Performance action sports product having a breathable, mechanically bonded, needlepunch nonwoven material combining shaped fibers and thermal and cooling fibers

ABSTRACT

The waterproof/breathable moisture transfer liner for alpine, snowboard and hiking includes an inner liner selected from technically advanced fabrics which are carefully selected. A series of layers are provided outside the inner liner including foam material and insulated nonwoven layers, breathable membranes, a supportive mesh included in a moldable foam, or moldable a spacer material and an outer shell fabric. The applicability of the liner to alpine boots, snowboard boots, cross country boots, hiking boots, protective gear, helmets, bouldering shoes, paddling apparel and gear along with appropriate variations for each application are disclosed.

RELATED APPLICATIONS

This is a continuation of U.S. Ser. No. 14/133,877, filed Dec. 19, 2013,which is U.S. Ser. No. 12/535,922, filed Aug. 5, 2009, which is acontinuation application of U.S. Ser. No. 12/003,262, filed Dec. 21,2007, which is a continuation application of U.S. Ser. No. 11/341,374,filed Jan. 30, 2006 (now U.S. Pat. No. 7,314,840), which is acontinuation application of U.S. Ser. No. 10/600,711, filed Jun. 23,2003 (abandoned), which claims the benefit of U.S. 60/390,221, filedJun. 21, 2002 and U.S. 60/421,076, filed Oct. 25, 2002. The entiredisclosures of all these applications are hereby incorporated byreference.

FIELD OF THE INVENTION

The present invention relates to liners used in a variety ofapplications. For example, the liner of the present invention may beemployed in a variety of applications including Alpine boot, soft-shellalpine boot light hiking and running shoes and hiking boots. The lineris breathable and transfers moisture to increase comfort for the skier,snowboarder, hiker and the like.

BACKGROUND OF THE INVENTION

Various types of liners are known for the prior art. However, theseliners do not provide the advantages realized by the present invention.The present inventor has recognized the problems faced by snowboarders,skiers and hikers and developed liners to overcome such problems.

There is an ongoing need for comfort, breathability, and support for thesnowboard or alpine lining. In prior designs, a rigid, non-breathableouter material, such as vinyl, foam, and nylon is often used. The innerliners have been leather, synthetic leather, nylon, or polyester blendswhich extremely limited the ability to breathe or wick moisture awayfrom a rider's body. These materials have also prevented the foot frombreathing adequately.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a first portion of the liner according to a firstembodiment of the present invention.

FIG. 2 illustrates a second portion of the liner According to a firstembodiment of the present invention.

FIG. 3 illustrates an example of the liner according to the firstembodiment of the present invention.

FIG. 4 illustrates the liner shown in FIG. 3 which will form a part of asnowboard or alpine liner.

FIGS. 5A and 5B illustrate a sole portion of a liner constructedaccording to a preferred embodiment of the present invention.

FIGS. 6 and 7 illustrate a tongue portion of a snowboard or alpine bootconstructed according to the first embodiment of the present invention.

FIG. 8 illustrates a more detailed view of the liner portion used forthe tongue of FIGS. 6 and 7.

FIG. 9 illustrates a portion of the liner used in the upper cuff area.

FIG. 10 illustrates the travel of moisture through a reticulated, opencell foam, spacer fabric then a flexible mesh and into and through abreathable membrane according to the first embodiment of the presentinvention.

FIG. 11 illustrates the toe portion of a snowboard or alpine lineraccording to a preferred embodiment of the present invention.

FIG. 12 illustrates an overall drawing of a snowboard, soft alpine,alpine or hiking boot insert liner which will incorporate the liner ofthe present invention.

FIGS. 13 and 13A illustrate an insert for an in-line skate or hockeyskate with a first portion enlarged.

FIGS. 14 and 14A illustrate another embodiment of an insert for anin-line skate or hockey skate with a second portion enlarged.

FIGS. 15 and 15A illustrate another embodiment of an insert for anin-line skate or hockey skate with a third portion enlarged.

FIGS. 16, 16A and 16B illustrate an insert for a soft-shell alpine bootwith a first portion enlarged.

FIGS. 17, 17A and 17B illustrate an insert for a soft-shell alpine bootwith a second portion enlarged.

FIGS. 18 and 18A illustrate a soft-shell alpine boot exterior shellcomposite.

FIGS. 19 and 19A illustrate a soft-shell alpine boot exterior shellcomposite.

FIG. 20 is a polymer shell for a hockey skate including a moisturetransfer liner.

FIG. 21 illustrates soft-shell in-line skate or the like exterior shellcomposite.

FIG. 22 illustrates the deep groove fiber.

FIG. 23 illustrates the deep groove fiber.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description of the preferred embodiments of thepresent invention is undertaken in connection with the drawings. Thisdescription, while undertaken with respect to the disclosed embodiments,is intended to enable a variety of different applications and slightmodifications which form a part of the present invention. Morespecifically, many of the materials used in this lining system have beendeveloped relatively recently, and in many cases are still beingmodified and improved. Where possible, tradenames of specific productshave been used to assist in the understanding of the invention. Thelining system according to the present invention can be easily adaptedto accommodate further developments in these materials. For example,while the preferred embodiments are illustratively presented below as aspecific sequence of layers, it should be understood that one or more ofthese layers may be omitted depending upon the specific needs of anyapplication. In other words, it is not strictly necessary to have acertain number of foam layers just as that disclosed in the currentlypreferred embodiments. This also applies for the other materials thatare described. For the sake of conciseness, every possible combinationcontemplated by the inventor is not specifically described. With this inmind, the preferred embodiments currently envisioned are set forthbelow.

FIG. 1 illustrates a portion of the liner, or lining system, accordingto a first embodiment of the present invention. This embodiment isdirected to a liner for a snowboard or alpine boot which is generallyremovable. The liner may be non-removable in some embodiments and maythe entire boot. The various layers of materials discussed below can beattached to one another in a number of ways, particularly by lamination,mechanical bonding (or stitch bonding such as that done by Tietex, Inc.,NONWOVENS INC., Foss Manufacturing or XYMED GROUP etc.) or a combinationof lamination and mechanical bonding. Mechanical bonding can beperformed using synthetic or natural fiber threads with or without theantimicrobial silver fibers, or the like. Mechanical bonding may beachieved by utilize the internal fibers from the nonwoven. A nonwovenblend with or without silver fibers and may be flocked into the opencell foam or the nonwoven composite may be laminated to the open cell.Hot Air or cold welding may be used in all applications to attach thelayers of the composites. As shown in FIG. 1, a first foam material (20)is provided between an inner liner material or knit or (10) and anonwoven attached to a second foam material (30). The inner liner (10)can be attached to the first foam, nonwoven or cellular elastomericmaterial (20) by lamination, mechanical bonding, welding or the like.The second foam material (30) is a germicidal, reticulated and or/opencell foam and has a thickness of approximately 1/32 TO ¼ inch. All ofthe foam materials used in the present invention are assumed to bebreathable and hydrophilic in nature or by treatment. A hydrophobic foammay be selected if it is breathable. All foams may be treated with ahydrophilic foam coating, or a wicking solution to increase the moisturetransfer properties and their thicknesses can be varied depending uponspecific needs. All foams may include silver fibers, nonwovens andnonwovens blends with or with out foam by Foss Manufacturing.Alternatively, some of the foam materials can be replaced with agermicidal, hydrophilic open-cell foam mechanically bonded to nonwovenfibers. For example, a foam (made by Foamex) may be used in combinationSSOFTHERM, a blend by Foss inclusive of antibacterial silver fibers andshaped polyester fiber. Preferably, a four deep groove (see FIGS. 22 and23) polyester fiber or a variation of a shaped polyester is combinedwith lyocel, pva, wool or a blend. Optionally, a shape synthetic fibersuch as corn, acetate, acrylic, or the like is wrapped in anothernatural or synthetic fiber or blend of synthetic fibers. Thecombinations lend endless possibilities to the performance criteria.Preferably, an open cell or the like or a hydrophilic foam by Dicon isattached to a moisture transfer nonwoven top sheet made of wood pulp,corn, polyester, nylon, cotton, rayon, wool polypropylene, LYCRA,elastine fiber, lyocel, kapok, acrylic, acetate or a combination ofthese, etc. The nonwoven selected fibers may be included in the opencell hydrophilic foam such as that by Dicon, Foamex or the like. AllDicon foam and the like can include silver fibers or a blend of fibers.

All synthetic and natural fibers may additionally be included in thefoam formation or fused together in the elastomeric composite with waterpressure. Alternatively, the nonwoven fiber blends, with or without thesilver fibers, may be flocked into selected open cell foam and can beadded to any foam, nonwoven, or fabric layer. All nonwovens in thisembodiment are believed to aid in the transfer of moisture throughabsorption and transfer moisture (wicking) or a combination of bothmoisture management mechanisms. The nonwoven has the option to betreated with COFOAM by Hydrophilix Inc., a patented process of coating ahydrophilic foam on fibers, nonwovens, fabrics, foams and materials.

Synthetic fibers for the most part are hydrophobic and encouragemoisture vapor and moisture to flow along, around and over but notthrough the fibers so as to be carried away for evaporation. Thisprocess is called “wicking”. Natural fibers and some synthetic fibersare hydrophilic and draw moisture vapor or moisture into themselves. Incombinations these fibers both absorb and wick moisture away.Independently, both natural and synthetic fibers encourage the movementof moisture vapor. Many of these nonwoven fibers may be chemicallymodified to increase their moisture transfer characteristics withwicking or ionized solutions.

The inner liner (10) is preferably constructed using specific fabricspossessing certain desired characteristics. A list of fabrics which canbe employed depending upon the individual needs of their application aswell as the individual needs of each person are provided below. Thesefabrics may either be used individually or in combination and can bedouble sided with one fiber on one side and another on the other side.Variations for use in an insert liners and composites for snowboard,alpine, hockey and in-line skates shell boots or the like. Thesoft-shell boot, moisture transfer composites are combined with apolymer skeleton framework. The moisture transfer liner is inserted intothe moisture transfer soft-shell boot and are specifically recited. Thesoft-boot insert liner requires that the external shell material becombined with a polymer skeleton framework.

The first fabric is an anti-microbial, anti-fungal fleeced polypropylene(also referred to as polyolefin) LYCRA blend (2%) with INNOVA fiber, orthe like. INNOVA is a continuous filament fiber (manufactured byDeercreek Fabrics, Inc., Coville or Menra Mills). Polypropylene is notedfor its excellent inherent moisture transfer characteristics.

All polyester or polypropylene fabrics made by Coville, Inc. orDeercreek Fabrics are treated with TRANSPOR DRY FIBER TECHNOLOGY, awetting solution or the like.

The second fabric is an anti-microbial, anti-fungal polypropylene fleecehaving a polyester, cotton, acrylic rayon or wool backing, or the like(such as that manufactured by Coville, Inc.) This double sided fabriccombines two moisture management mechanisms, wicking and absorption. Thewickable synthetic fiber pushes the moisture away and the cotton, rayonetc. pulls the moisture up from the inner layer and spreads it out fortransfer and evaporation. This double sided fabric may be used forwinter hiking or climbing boots and various alpine boots, the backingmade of polyester or cotton blends can be replaced with either naturalor synthetic blends of fibers such as wool, cotton, silk, acetate,acrylics, tencel, rayon, polyester, corn or kapok fibers or the like.

The third inner lining material may be a nonwoven such as that made byFreudenberg called Vildona or Evolon made from microdenier polyester,nylon synthetic blends or nonwovens made of natural fibers and naturalfiber blends such as cotton, kapok, wood pulp and by-products such asthose by NatureWorks called (PLA) CORNUCOPIA made from a corn fiber.

The fourth fabric is an anti-microbial, anti-fungal polypropylene/cottonblend with ALPHA fiber (such as that manufactured by Intex Fabrics, Inc.or the like).

The fifth fabric is a FIELDSENSOR polyester with waffle weaveconstruction (such as that manufactured by Toray and distributed by Yagi& Co., Inc.). Alternatively, a polyester material known as AQUA-DRY,manufactured by Teijin Shojin can be employed.

The sixth fabric is a hydrophilic anti-microbial DRI-LEX BABY KID,DRI-LEX nylons or perforated material (such as that manufactured byFaytex Corp.)

The seventh fabric is a polyester looped terry (such as thatmanufactured by Kronfli Spundale Mills, Inc.).

The eighth fabric is a sueded/sanded fleeced polyester microfibermaterial (distributed by Yagi & Co., Inc. and Teijin Shojin, Inc.).

The ninth fabric is POLAR TEC SERIES 100, 200 and POLARTEC POWERSTRETCHwhich is a wickable, moisture transfer fiber, containing LYCRA andpolypropylene. This fabric is also anti-microbial.

The tenth fabric is a moisture transfer fabric CERAMIC FLEECE byCalamai.

The eleven fabric is a wool blend with a cotton, polyester, or the likebacking.

The twelfth fabric is an acrylic-based conductive fabric from Sterling

Performance.

The thirteenth fabric is a nylon or nylon polyester blend possiblytreated with TRANSPORT DRY FIBER technology manufactured by GilfordMills.

The fourteenth fabric is a spacer fabric constructed of nylon,polyester, or polypropylene blend.

The fifteenth type of fabrics are selected chemical and naturallyionized synthetic fabrics and fibers such as (MICROSAFE ACETATE,MICROSUPREME ACRYLIC CYSTAR, BIOFRESH and the like manufactured byCelanese Acetate, Sterling Performance Fabrics, MICROSUPREME HIGH TECHACRYLIC by Sterling Performance fabrics.

The sixteenth type of fabrics are ACRILLIAN or DURASPUN acrylicsperformance fabrics by Monsanto or blends of acrylics and polyester byGlenoit, or the like.

The seventeenth fabric is blend of performance fibers and TEFLON orFREELON blend of Friction Free Technology by Concept III.

The eighteenth fabric is a new blend of corn fabrics or corn and cottonfibers with wool by Draper Knitting.

The nineteenth fabric is peppered fleece a combination of cotton,acrylic or cotton, acrylic and polyester

The twentieth fabric is KWILL fleece by Concept III.

The twenty-first fabric is K-WICK by Kronfli Spundale Mills.

The twenty-second fabric is MICROLANA MICROFABRIC by Glenoit.

The twenty-third fabric is MICROSUPREME HIGH TECH ACRYLIC by SterlingPerformance Fabrics blends of acrylic, cotton and polyesters fleecedfabrics.

The twenty-fourth fabric is NANO-DRY by Nan-Tex, a blend of cotton andsynthetics.

The twenty-fifth fabric is DRI-RELEASE by Concept III Textiles.

The twenty-sixth fabric is by Dyersburg called DYERTECH.

The twenty-seventh fabric is DRYLINE by Milliken a hydrophobic polyesterand LYCRA.

The twenty-eighth is SWEET a polyester fabric by Tapetex.

The twenty-ninth is a polyester and polypropylene fabric blend byCoville, preferably COMFORTREL. Also preferred are moisture transferknits by Coville and blends of cotton and polyester and/orpolypropylene, preferably HIGHLANDER-PLUS or POLYGON STRETCH.

The thirtieth fabric is cross-dye POWER DRY and SMART FIBER fabrics byWellman.

The thirty-first fabric is MICROMOVE by Burlington.

The thirty-second are polyester fabrics and blends by Kronfli.

The thirty-third is M.C.S. WITH NANO DRY.

Finally, spacer fabrics or fleeced fabrics of polyester or polyesterblends manufactured by Malden Mills and others can be used.

All synthetics and natural fibers and fabrics may have the option to betreated with Phase Change Technology. The addition of the Phase ChangeTechnology to melt blown fiber is presently marketed by OUTLAST asTHEMOCULE or by Freundenberg Nonwoven. The OUTLAST/DTI melt-blown spunbond fiber, Freudenberg Nonwoven thermal fibers with Phase Change,Thinsulate or Thinsulite with Phase Change Technology or ThemoSense byWisconsin Global Technology is an option in any layer in this system.All thermal layer with or with out Phase Change Technology may includesilver fibers and may be ionized with addition fibers or a chemicalsolution to increase moisture transfer. The synthetic or natural fibersin the inner lining layer 10, may be treated with Transfer Dry FiberTechnology, Intera Technology or any wicking solution that increasesmoisture transfer capabilities. Alternatively, chemical ionizedsolutions may be applied to any layer or layers in the system toincrease the moisture transfer properties of layers. Chemicallyionization of synthetic fabrics involves permanently placing a slightcharge in a fabric after the solution is applied. A combination ofchemically ionized or wetting solutions may be applied to the anyfibers, fabric or foam in the liner system to enhance the moisturetransfer performance of the fabric. Micro-spheres or micro-encapsulatedpolymer sphere technology may be added to any fiber, fabric, nonwoven,foam, coating, membrane or treatment in this liner system. The spheresmay be formed from a synthetic polymer such as corn, acrylic, silca,wax, silver fibers or the like or the may be wrapped fiber or foam. Theencapsulated micro-spheres or micro-spheres may contain air, wax or anumber of solutions that assist in regulating temperature and aredeveloped with materials to assist in the absorption and/or moisturetransfer.

A preferable option to the inner lining fabric is a moisture transfernonwoven or elastomeric composite blend by FoxRun Technologies (U.S.Pat. No. 6,074,966, the disclosure of which is hereby incorporated byreference) with natural or synthetic fibers. The elastomeric compositeis made in one process and includes foam and fibers fused together withwater pressure. The elastomeric composite may contain any of the fibersmentioned as well as the antimicrobial silver fibers or treatments. Theelastomeric fibers may be treated with wicking solutions, chemicallyionized, or fiber or fiber blends may be wrapped around individualfibers in the elastomeric to increase the moisture transfer and/orabsorption, thermal values, flexibility, tear strength or otherperformance properties. The elastomeric composite may be welded orneedled to an abutting foam or a moisture transfer composite of foam anda nonwoven or SSOFTHERM blend or a SSOFTHERM blend with foam(THERMALFOSS), nonwoven thermal with foam such as Thermolite,Thinsulite, or the like. Thermolite fibers or fibers by DuPont/DTI, 3M,Freudenberg, Alhstrom or Kosa may be included in the SSOFTHERM or Fosscomposites. Alternatively, the thermal composite may be constructed withfibers from DuPont, GORE, Toray or 3M thermal nonwoven products with orwithout thermal melt-spun fibers and/or Phase Change Technology and opencell foam or elastomeric composite. The fibers include the abovementioned fibers with or without an antimicrobial fiber added. HOLOFIBERby Wellman may be include in the nonwoven or elastomeric composite. TheHOLOFIBER, silver fibers and/or shaped lobed fibers by F.I.T., or thelike, may also be introduced into the foam or composite foam layers. Theelastomeric composite and nonwoven composites may contain split thermalfibers. Alternatively, the elastomeric composite may be needled into thefoam, nonwoven composite or the THERMALFOSS nonwoven blend manufacturedby Foss Manufacturing, Thinsulate, DuPont, GORE, Freudenberg, Toray or3M thermal fibers, or the like. The thermal fibers or nonwoven productsby DuPont or 3M such as Thermolite or THINSULATE nonwoven groups maybebe mechanically bonded, welded or laminated to the Foss thermalcomposite blend or a single layer in the Foss nonwoven composite may beused as a scrum on one side or both sides of the Thinsulate orThinsulite products.

Alternatively, a wet-laid or spun-bond nonwoven comprised of thesynthetic fibers, natural fibers or a blend may be mechanically bondedto the thermal nonwoven with or without open cell foam or an open cellfoam, nonwoven and foam composite or a combination of one or more.Optionally, The cellular elastomeric composite may be combined with thethermal nonwoven in some performance categories.

An example of one preferable embodiment would constitute a thin layer ofthe shaped or lobed polyester fiber or polyester blend mechanicallybonded to a Thinsulite or 3M nonwoven product, DuPont thermal nonwoven,Gore, Freudenberg, Toray or another thermal nonwoven or the like. Thewet-lay or spin bond nonwoven or nonwoven scrum provided a moisturetransfer top sheet to one side or both of the thermal nonwoven. The thinlayer of nonwoven fibers may be apertured. A elastomeric composite mayreplace this thin nonwoven layer or a composite of fiber blendsinclusive in an open cell foam suggested may be substituted for nonwovenscrum on one side or both of the thermal nonwoven or foam layers in thisliner system. In another embodiment a nonwoven apertured wet-laid fiberor spun bond blend is applied to the Foss composite, 3M or GORE, Toray,Freudenberg, DuPont nonwoven products on one or either side. Theselected fibers may be treated with wicking solutions, chemicalionization or may be wrapped fiber combinations. Of course, the thermalnonwoven may utilize neither the nonwoven top-sheet, foam with fibersblends or elastomeric composite in this application.

Thermal nonwoven layer is one of the previous combinations isThinsulite, Themolite, ultralite a blended variation of selected fibersor the like, SSOFTHERM or the Foss composite blend.

The Thinsulite 3M's line of thermal nonwovens or the DuPont thermalnonwovens may be altered to contain one or more of the following fibers;silver fibers, lobed polyester fibers preferably by F.I.T, polyester,lyocel, PVA, rayon, acetate, corn, acrylic or any variation orcombination suggested in this application.

The Foss thermal blend with silver fibers and lobed polyesters, PVA,and/or lyocel or wool with or without foam is the preferably option inany of the layers 20,30,50 in this liner system. The Foss or Freudenbergnonwoven or nonwoven composite can abut on one side or both an open cellfoam or the inner or exterior shell fabric and can be treated with awicking solution. In a number of performance categories the Fossnonwoven composite may be treated with a breathable membrane.Optionally, the Foss, Freudenberg nonwoven or the like may include PhaseChange fibers Technology or Micro-sphere Technology.

Optionally, the Foss Thermal nonwoven composite may be omitted and theselected nonwoven fibers in the Foss composite may be flocked into thefoam layer or layers of the insert lining or outer shell bootcomposites. In some performance categories the selected nonwoven fibersand/or the shaped or lobed polyester or polyester blended fibers with orwithout silver fibers are flocked into the foam layer or layers and abutthe Foss composite or a thermal nonwovens mentioned above. Optionally, awet-lay nonwoven preferably aperture, or elastomeric compositecontaining at least one of the selected nonwoven fibers previouslymention and be needled or welded into the foam or thermal compositestructures in on either side or both this application. Alternatively,the nonwovens fibers are flocked to the back inner lining or exteriorshell material or fabric to increase the moisture transfer properties.In fact, nonwoven fibers and blends may be combined with any layer inthis application by lamination, welding, flocking, fusing, or the like.

Selecting the proper materials, fibers, foam and fabric combinations andblends depends upon the needs of each individual riders and skiers. Thenon-abrasive fabrics moisture, used in the moisture transfer inner linerof the present invention greatly reduces the possibility of trappedthereby protecting the foot from fungus growth and any damage. Theanti-fungal, anti-microbial polypropylene (polyolefin) fabrics quicklyremove moisture away from the foot. Skin damage is minimized because thepolypropylene fabric or the friction-free fibers including Teflon,generic teflon or FREELON. The smooth, continuous surface or a softmicro denier fleece by Deercreek, Coville or the like prevents bacterialbuild-up which can cause foot odor and fungus. Chemical ionized orwetting solutions maybe combined with the polyolefins and polyesterfiber blends to increase performance levels. In further discussion it isimportant to assess the product and performance criteria required inselecting the materials and moisture transfer composite options.

All of these fabrics have good moisture transfer characteristics andprevent damage to a rider's foot by preventing excessive moisturebuild-up.

The moisture transfer characteristics of the inner liner (10) causesmoisture vapors to pass from a rider's foot through the inner liner (10)where it then comes into contact with the first foam, nonwoven ornonwoven and foam composite (20). The moisture vapors travel through thefirst foam, nonwoven or nonwoven and foam composite (20) and comes intocontact with a second foam, nonwoven or composite material (30).Preferably, layer 30 can be composed of the moisture transfer nonwovenblend by Foss Manufacturing, Freudenberg, GORE, or the like needledtogether with an breathable open cell foam. The nonwoven may be a spunbond or wet-lay preferably attached to the foam by lamination ormechanically bonded. In some applications stitching or welding ispreferable. The nonwoven may also be included in the open cellhydrophilic foam such as those recently developed by Dicon Technologies,Foamex or the like. It preferable to add a anti-microbial silver fibersuch as those by manufactured by Foss Manufacturing or X-Static.

The nonwoven may be eliminated in some performance categories and layersof foam with or without silver fibers and polymer mesh may abut theinner and exterior shell fabrics or materials. In some options thethermal fibers may be eliminated as well as the open cell foam and afoam substitute made of nonwoven materials may be used.

Preferably, the foam in layer 20 is 1/32 to ⅛″ is a germicidal,reticulated, hydrophilic, open cell foam developed by Foamex, Dicon orthe like) and backed with a nonwoven top sheet comprised of wood pulp,rayon, wool, cotton, corn, polypropylene, lyocel, polyester, flax,acrylic, acetate, elasthane or a combination there of or the like. Allthe prior nonwoven fibers wick or absorb moisture or both and providemoisture transfer characteristic to the liner system.

The foam material 20 can be attached to the moisture transfer nonwoventop sheet by lamination, stitched, hot welded, flocking orultrasonically bonded. The moisture transfer nonwoven top sheet (whenused) abuts the next layer of 1/32″ to ¼″ reticulated/hydrophilicflexible polyester, open cell foam, or second foam material or anonwoven by Foss Manufacturing, Freudenberg, Gore, 3M or Toray, Alhstromor DuPont or a moisture transfer thermal nonwoven composite 30. Fossnonwoven may optionally, be combined with nonwoven fibers by 3M,Freudenberg Gore or DuPont thermal fibers. Themolite by Dupont,Thinsulite by 3M or the nonwoven by Gore or Freudenberg may containsilver fibers. The second foam material 30 may also be a germicidal,hydrophilic, open cell ¼″ foam, such as Aquazone, VPF, DRI-Z or thelike. The second foam material is preferably backed with a moisturetransfer nonwoven top sheet as mentioned above creating alternatinglayers of foam and nonwoven. As mentioned above these alternating layersof foam and nonwoven fibers transfer moisture, regulate temperature,increase performance and develop a moisture transfer system with orwithout thermal application. The moisture transfer nonwoven top sheet ispreferably aperture and the foam is a breathable, open cell foam. Thesnowboard boot, alpine boot, soft alpine boot and shell boot, climbingand hiking boot liner may utilize the inner composite comprised ofalternating layers of foam and nonwovens to trap moisture and prevent itfrom returning to the inner lining surface. The foam and moisturetransfer nonwoven composite combination may be used in numerouslocations to absorb and transfer moisture. This foam and moisturetransfer composite creates a one-way system that allows moisture totravel only in an outward direction. Also, many of the foam materialsare interchangeable depending upon specific performance needs.Optionally, a number of the three and four layer fabric, nonwoven andfoam composite combinations may be used for exterior soft-shell bootcomposite.

The foam materials can be flame laminated to a moisture transfernonwoven top sheet of cotton, woodpulp, lyocel, corn, kapok, wool,polypropylene or polyester, or a blend thereof. The top sheet is a spunbonded is a wet-lay nonwoven. The wet-lay nonwoven is preferableapertured. The nonwoven top sheet and may be replaced with a woven orknit constructions comprised of synthetic or natural fibers or fiberblends in this embodiment. Wool fibers are an option in this layer. Themoisture transfer nonwoven is not to be confused with a moisturetransfer thermal composite mechanically bonded nonwoven manufactured,Foss Manufacturing, 3M, Freudenberg, GORE, DuPont or the like. In someperformance categories the moisture transfer thermal nonwoven compositemay abut the inner moisture transfer fabric and the nonwoven and/or foamcomposite will be omitted. The Moisture Transfer Thermal composite mayalso abut an open cell foam or elastomeric composite. The foam layer isa breathable, hydrophilic, open cell foam preferably DuPont, or VPF byFoamex or DRI-Z by Dicon Technologies or the like. The DiconTechnologies open cell foam may optional be developed with glycerin.These foam can also be backed by moisture transfer nonwoven top sheet orabut another open cell foam in a number of performance categories.

An option to the three layers of inner lining material, foam andnonwoven (10,20,30) is a lining composite made by Faytex material calledDRI-LEX or a liner composite by Dicon Technologies called DRI-Z or acomposite by Schoeller Textil call SCHOELLER COMFORTEMP abutting a opencell foam and a nonwoven thermal or spacer fabric material. The DRI-LEX,Schoeller and Dicon composites are comprised of a inner fabric, foam, anonwoven or knitted top sheet may be added to this system in someembodiments. The Schoeller and or Dicon composites may be with orwithout the Phase Change Technology. All the composites are believed tobe breathable. The addition of the selected nonwoven fiber blendsmentioned above with transfer moisture and increase performance. Thefabric, foam and nonwoven layers selection by Dicon, Faytex or Schoellermay include in some performance categories.

Alternatively, the first foam material (20) may be a cellularelastomeric composite. The elastomeric composite in layer 20 may becombined with the foam or thermal nonwoven in layer 30. The elastomericcomposite is an exceptional moisture transfer composite layer comprisedof foam and nonwoven fibers developed by FOXRUN. In one optionelastomeric composite may attached to the Foss nonwoven composite withor with out and foam in layer 30 and the inner lining material layer 10.This moisture transfer thermal nonwoven composite manufactured by FossManufacturing may replace the alternating layers of foam and moisturetransfer nonwovens in layers 30 in some performance categories. Thisthinner liner option may be used to accommodate the alpine race bootliner. The elastomeric composite is created by fibers fused togetherwith water pressure and can be reviewed in U.S. Pat. No. 6,074,966. Theelastomeric is a nonwoven elastomeric web material comprising ahydraulically entangled admixture of a elastomeric foam as a base and asecond component of individual natural and/or synthetic fibers subjectedto pressured liquid water jets causing entanglement and intertwining ofthe first component and the second component so as to form an integratedelastomeric web material. The elastomeric may include VPF open cell foamby Foamex.

A split thermal fiber and/or lobed polyester fiber manufactured by FossManufacturing and the like maybe combined with the selected fibers inthe elastomeric composites in the moisture transfer system. Theelastomeric composite can be mechanically bonded or welded to the Fossthermal nonwoven composite, foam composites comprised of alternatinglayers of open cell foam and moisture transfer nonwovens or spacerfabric for a thinner race boot application, cross country boot or hikingor climbing shoe. Alternatively, the alpine race boot moisture transferliner may be comprised of inner lining material layer (10) and the Fossthermal nonwoven composite layer (30) abutting a spacer fabric layer byMuller, FoxRun, Hextel or the like and layer (50) the outer fabrics. Theelastomeric composite can be inserted between layer 50 and layer 80 toincrease moisture transfer to the exterior sheet liner fabric.

Optionally, layer 10,20, and 50 can be used in a helmet liner forsnowboard and the like abutting the exterior shell polymer of thehelmet.

The Phase Change Technology by Frisby/Schoellar, OUTLAST, Freudenberg,Dicon, Wisconsin Global Technologies and the like may be in combinationwith the Elastomeric Technology by FoxRun Technologies. The Phase ChangeTechnologies may also be applied to the fibers or foam of theelastomeric composite. The elastomeric composite maybe cold welded ormechanically bonded to the open cell foam or the abutting thermal orspacer fabric. The Phase Change Technology is optional in theseelastomeric, foam, thermal or spacer fabric composites and products. Theelastomeric may contain thermal fibers by DuPont, Foss, or 3M and mayhave an antimicrobial silver fiber added in some categories. PRIMALOFTmay be an option in this thermal category include with foam and/or foamand nonwoven fibers. The OUTLAST, Frisby Technologies, Schoeller, DTI,Dicon or Freudenberg Nonwovens or the like microencapsulatedphase-change materials in fibers, coatings, fabrics, nonwovens or foamscan be laminated, welded or mechanically bonded to the outer fabric,nonwoven or to the abutting foam. The Phase Change Technology may beembedded in the encapsulated fabrics or in combination with structurallyknitted or woven waterproofed fabrics or nonwovens. The Phase Changetechnology may be include in fibers flocked to the back of foam ornonwoven materials and may be added to the hydrophilic foam coating byHydrophilix, Inc. The temperature regulating membrane or coating calledOUTLAST, by Gateway Technologies can be inserted between inner layer 10and the first foam material 20, or applied to the fibers or fabric oflayer 10 or the material or composite blend in layer 10. Phase-changefibers may be flocked to the fabric, material, nonwoven or foam layers.

Alternatively, Phase Change Technology can be embedded in the first opencell, hydrophilic foam layer 20 placed in the second foam material 30 orin the abutting or composite if used. The hydrophilic foam is preferablyDuPont a flexible polyester, but can be open cell by Dicon or the likeor a Frisby product called COMFORTEMP.

The OUTLAST membrane or coating can be placed on the other side foam,outside or on top of the moisture transfer nonwoven top sheet, ifpresent. In fact, Phase Change Technology by OUTLAST or Schoeller,Freudenberg Nonwovens, Dicon Technologies, or Frisby may be combinedwith any fabric foam, nonwoven or insulated layer and can be on eitherside. The OUTLAST or Freudenberg Nonwoven melt-blown fibers with PhaseChange Technology referenced in patent Ser. No. 09/699,744 and theinternational counterpart PCT No. US01/41497 or the like can be added tothe foam or flocked to the back of the foam, nonwoven and fabrics.

Alternatively, THERMOSENSE by Wisconsin Global Technologies may beapplied to the fibers, fabrics and nonwovens in this liner system.THERMOSENSE is a phase change technology.

A number of patents have been issued to Triangle Research & DevelopmentCorp. disclosing details related to the processes now being employed byGateway Technologies and Frisby. For example, U.S. Pat. Nos. 4,756,958and 5,366,801 are directed to fibers and fabrics with reversibleenhanced thermal properties, respectively. The disclosures of these twopatents are hereby incorporated by reference. Other patents assigned toTriangle Research & Development Corp., that are related by subjectmatter and have overlapping inventorship, include U.S. Pat. Nos.541,522; 5,290,904; and 5,244,356. These patents are also herebyincorporated by reference.

Another U.S. Pat. No. 5,499,460, which has overlapping inventorship withthe above-mentioned patents, is directed to a moldable foam insole withreversible enhanced thermal storage properties. The disclosure of thispatent is hereby incorporated by reference, and is illustrative of onetype of moldable foam that can be used as mentioned herein.

As shown in FIG. 2, a third foam material 50, which provides support andhas similar characteristics to the second foam material 30, allows themoisture vapors to continue their movement toward the outside. Thisthird foam material 50 alternatively can be a moldable foam, Fossnonwoven composite with or without a foam, a foam composite comprised ofalternating layers of foam and moisture transfer spun bonded or wet-laynonwovens, a thermal nonwoven or a thermal nonwoven comprised ofmoisture transfer nonwoven blended fibers and foam mechanically bondedtogether. Optionally, a thermal nonwoven such as SSOFTHERM, SSOFTHERMblend, Thermolite, Gore, Freudenberg or 3M thermal fibers insulationmaterials or the like with or without foam have a performance nonwovenor scrum needled or weld to one side or both sides in layer 50. Abreathable spacer fabric or a combination of the composites materialsmaybe applied to layer 50 in some performance categories. The spacerfabric by Muller or the like, honey-comb spacer material by FoxRun orthe like or STYROFOAM is easily molded to take the necessary shapes suchas the shape of an ankle, heel cup and foot bones, and is positioned soas to allow the moisture to pass through into subsequent elements andincrease comfort and performance levels. Layer 70 is awaterproof/breathable membrane or coating and is optional in this linersystem. The breathable ultra thin, micro-porous synthetic membranes orcoatings have millions of tiny holes that allow moisture vapor to escapeto the outer fabric surface. The permeable, hydrophobic membrane islaminated to the outer shell fabric or abutting foam, thermal nonwoven,or moisture transfer nonwoven. It is not recommended that the membraneor coating be applied to the spacer fabric by Muller or the like. Themembranes if applied are preferably hydrophobic with millions of holesor pores built into the surface allowing water vapor and heat to escape.However, breathable hydrophilic membranes may be used in someperformance categories. Alternatively, the membrane may be replaced maybe a waterproof breathable permeable hydrophobic coating with tiny poresbuilt in applied the shell fabric or material or abutting foam ornonwoven or nonwoven thermal blend.

The waterproof breathable hydrophobic coating is a preferablealternative to the breathable membrane in some performance categories.Optionally, an application utilizing a hydrophilic monolithic ornonporous coating applied to the back of the fabric or nonwoven. Thecoating allow controlled breathabiltiy in a molecular transfer process.The selected options are MFT, LAYTEK EXELTECH, DUREPEL 1000, ENTRANTGIL, AQUADOR, CELTECH, AQUADOR, SYMPATEX WINDLER, EVENT, SYNTHETICELASTIC, ENDURANCE, TRIAD, STORM-TEX, ACCUVENT BY ENTERPRISE COATING orwaterproof breathable membrane by Gore-Tex (Gore-Tex ImmersionTechnology) or the like may be applied. The outer layer 80 of theoverall lining system can be treated with a waterproof breathable filmor finish, a coating, a membrane or a encapsulation by Toray, NextecU.S. Pat. No. 5,004,643 or the like. The preferable embodiment is the orfiber or fabric encapsulated of the outer fibers fabric preferably byNextec or Toray. Encapsulation may be applied to the fibers in a layerinternally in a fabric. The layer of treated fibers in a fabric maybe onthe face, in the middle or in the base of fabric creating varyingdegrees of waterproofing. The yarns may be coated with silicon or a weblayer may be included in a fiber layer in the fabric or the like towaterproof the entire fabric layer as in U.S. Pat. No. 5,004,643, whichis hereby incorporated by reference A waterproof breathable DWR finishor film applied to the shell waterproof breathable finish may be appliedwith an encapsulated fiber in some performance categories. A fabric isalternative option to the encapsulated fabrics. Suggested products suchas DURAPEL PLUS, TRAVTECH, HYPER D-WR, ENTRANT G2-XT or eVENT fabrics.

As previously stated layer 50 may be a foam, a foam composite withpolymer mesh with or without fiber blends, Foss nonwoven composite or aspacer fabric and may be moldable. The third reticulated/open cell foamor material in layer 50 can be designed to provide a well defined heellift, and heel pocket. This invention develops the components necessaryto increase the technical performance of the products. The increasedsupport and moisture transfer around the heel, toe, and ankle allows therider to maintain a continuous comfort level during performance. The toebox is from top to bottom, wider and more flexible than in previousalpine or snowboard liners. The laminated or mechanically bonded foams,nonwovens and spacer fabrics under the heel support the rider's lowerback and allows for a comfortable stride. With this added comfort, theaggressive or recreational rider's or skier can achieve a higher levelof continued performance.

As shown in FIG. 3, between the supporting second foam material 30 andthe third foam material 50 is a structural mesh 40 which can be a flexguard, for example such as one manufactured by Naltex or Conwed or thelike, that adds structural integrity to the lining system. In one optionthe structural mesh may be include within the foam layer 20,30 or 50 orattached to the foam or spacer fabric. Alternatively, the structuralmesh may be between layer 20 and 80 in some performance categories. Thefoam including the mesh may be a hydrophilic and open cell foam. Theflex guard and foam composite may be used in place of the spacer fabric,moldable foam, thermal composite in layer 50.

The mesh may be applied by lamination or welding to the spacer fabric orfoam between layer 50 and 80 or to the third foam layer 50. Also, themesh may be not used in some circumstances.

A moldable foam such as PORON, if used can be made punctured to allowbreathability and moisture transfer in the heel, tongue or toe.Alternatively, the foam can be a reticulated or hydrophilic, open-cellflexible polyester foam structure, or the like in the toe box, heel andankle pocket. A moisture transfer nonwoven top-sheet (with or withoutapertures) can be attached to the moldable foam. If a moldable foam or aspacer fabric is used, then the second foam material may be omitted insome thinner applications. Also, the moldable foam can be a hydrophilicfoam such as DuPont. As mentioned earlier, the third foam material 50 ispreferably similar in construction to the second foam material namelybeing either germicidal, reticulated and approximately ⅛ to ¼ inchthick, or being germicidal, hydrophilic open-cell (for example DuPont,VPF or DRI-Z). This material is preferably laminated to a moisturetransfer nonwoven top sheet (which may or may not be apertured)comprised of corn, polyester woodpulp, lyocel, rayon, kapok, cottonfibers or a blend. The top sheet abuts the waterproof/breathablemembrane in layer 70 or waterproof breathable finished, filmed, coatedor an encapsulated outer shell fabrics.

It is recommended for extreme sports performance and protective gearproducts that the moldable foam or spacer fabrics used in place of thebreathable flexible mesh and the open cell composite in layer 40. Layer40 may be also a spacer fabric welded to a flexible mesh or a spacerfabric combined with flexible mesh and foam composite may be combined.The breathable flexible mesh be alternatively incorporated into the opencell foam. The flexible mesh incorporated into the foam in one processcreates moldable foam composite and may be used in place of the spacerproduct. The spacer fabric, or foam nonwoven composite or mesh and foamcomposite may be combined with the Foss Thermal nonwoven composite forthe alpine race boots, ice boots or the like. The nonwoven and foamcomposite are highly moldable, breathable, and transfer moisture. Thespacer fabrics can be of synthetic or natural fiber blends such as thosemade by FoxRun Technologies and the like. In one options a spacer fabricmay abut the inner lining material, or inner lining two layer compositeof liner material and foam or lining material, foam and nonwoven blend.Another option includes the inner material, abutting the elastomericcomposite on one side and the exterior shell fabric on the other side tocreate a thin performance liner. The elastomeric composite may be weldedor flocked to the inner lining material or shell fabric. A breathablemembrane between the exterior shell fabric may be waterproofed with afinish, film, or encapsulation or none of the options may be applied Icertain performance categories.

For snowboard, alpine and hiking boots, due to the cold weatherconditions, a combination of thermal moisture transfer nonwovennonwovens, foam composites and spacer fabrics are recommended.THERMOLITE, QUALLOFIL, THERMALOFT, SSOFTHERM, THINSULATE, PRIMALOFT orthe like and foam mechanically bonded, or laminated together or a foamcomposite comprised of a SSOFTHERM blend by Foss Manufacturingmechanically bonded together with open cell foam is preferred. Anelastomeric composite may be flocked or needed to the thermal nonwovensmentioned above to assist in moisture transfer performance. The Fossnonwoven blended layers without open cell foam may be used in someperformance categories. The Foss nonwoven blend maybe an alternative ina number of layers in this moisture transfer breathable system and insome products the open cell foam may include a flexible mesh abuttingthe nonwoven composite. The Foss nonwoven blend with thermal fibers andfoam added is here by referred to called THERMALFOSS. The Foss nonwovenblend, SSOFTHERM with or without foam or THERMALFOSS may be applied tolayer 50 as previously discussed or abut the spacer fabric in layer 50as layer 30. THERMALFOSS is a blend of four deep groove polyesterfibers, silver antimicrobial fibers and a combination of the abovemention nonwoven fibers. The THERMALFOSS composite may be added betweenlayer 70 or 80 in some performance categories. In applications requiringa thinner composite options, such as in race boot liners, alpine crosscountry, ice skates, hiking and climbing shoes and boots, boulderingshoes and paddling sports equipment apparel and helmets, accessories theTHERMALFOSS may be applied to layer 20, or 30, 40 and abut the innerlining of moisture transfer fabric.

Optionally, the Thermolite or the like or Foss nonwoven composite withor without foam or THERMALFOSS may be mechanically bonded, welded orlaminated to a spacer fabric preferably by Muller Textil. An option tothe spacer fabrics by Muller Textil or the like are spacer fabrics byFoxRun Technologies. These honey-comb constructed spacer fabrics ofsynthetic and natural fiber blends are recyclable and environmentallyfriendly. Spacer fabrics constructed with corn, cotton, flax, kapok,woodpulp, polyesters fibers and the like are preferable. On goingresearch to develop recyclable, bio-degradable alternatives toconventional spacer fabrics is goal of this breathable liner system.Presently, the research by Naturework on by-products of corn fibers andFoxrun on alternative re-cycled polyester and natural fibers andconstruction are be evaluated for layer 50. A special blend of DuPontfibers and corn fibers with or without foam may be an option in somecategories. A thinner option for bouldering shoes, all weather boots,etc. may be the four deep groove polyester manufactured with silverfibers by Foss Manufacturing mechanically combined with a open cell foamand a waterproof mesh. An elastomeric composite with a selected group ofprevious suggested fibers including wool may also mechanically bonded tothe Foss, GORE, 3M or DuPont Nonwoven or the like polyester fibers.

As discussed layer 50 may be a thermal nonwoven such as Thinsulite orThermolite or the like. Thermolite, manufactured by DuPont, is a thininsulation having a hollow polyester fiber laid in random layers with anacrylic binder (loose felted) needle punched through the cross sectionto attach layers and tie them down. Various types of Thermolite can beused, such as Thermolite extreme, Thermoloft, Microloft, TFI 2000 G/M2,TFI 4000 G/M2, QUALLOFIL etc. in layer 50 in a number of products andvarious performance level. The thermal may be mechanically bonded to thespacer fabric by Muller, FoxRun Technologies or the like and can abutlayer 70 or 80. In a number of thinner liner options such as a iceskate, hiking shoe, climbing boot, etc., the combined composite of amoldable spacer material and thermal nonwoven composite and may be usedabutting the inner moisture transfer fabric or material on one side andthe exterior shell fabric on the other. The layered moisture transferbreathable system can be molded in one process. A preferable embodimentfor the race alpine boot liner or the hiking shoe develops a three layerinner lining composite abutting the thermal nonwoven or thermal nonwovencomposite and the outer shell fabric. Alternatively, a three layercomposite consisting of a inner lining fabric, open cell hydrophilicfoam and a nonwoven by manufactured by Dicon Technologies, SchoellerTextil or Faytex DRI-LEX. These composite construction may abut thefoam, spacer fabric or thermal nonwoven product as an option in thismoisture transfer system. Fabric composites maybe used next to an opencell foam and/or spacer fabric and an exterior shell fabric for a hikingshoe, ice skate etc.

Alternatively, the elastomeric cellular composite may be mechanicallybonded to the thermal nonwoven composite or replace the open cell foamlayer embedded in the thermal composites or Thinsulite, Thermolite orthe like. The elastomeric composite may be welded or mechanically bondedto the nonwoven or foam composite with open cell foam or the thermalnonwoven composite to increase moisture transfer capabilities.Alternatively, the elastomeric and silver fibers may be flocked to theopen cell foam or inner lining fabric. The elastomeric and foam ornonwoven combination may replace any layer or layers in this moisturetransfer system. Preferably, the elastomeric composite are used in athinner application for technical apparel, golf, running and tennisshoes and the like.

Layer 70 is a breathable membrane if used. The Phase Change Technologyby OUTLAST Technology may be added to layer 70. The breathable membraneand Phase Change Technologies may be combined to increase the thermalattributes of the moisture transfer system. The Phase Change Technologyby OUTLAST Technology, Frisby Technologies, Wisconsin GlobalTechnologies, Schoeller Textil, Freudenberg or Dicon Technologies or thelike can be applied to the fabrics, nonwovens, foams, elastomericcomposite, thermal nonwovens or fibers blends in the liner. In the caseof Frisby Technologies the foam may be COMFORTEMP or COMFORTEMP DDC. Inthe case of OUTLAST Technology, the Phase change microencapsulatedtechnology may be applied to fibers, fabrics, nonwovens, breathablemembranes or carried in a binding agent applied to a foam, fabric ornonwoven surface. The OUTLAST Technologies (Phase change Technology) maybe applied in a coating, membrane or directly on the fabric or in thefiber. In one option, Phase change Technology is added to wood pulp orcotton fibers or a blend with or without elastine fibers may replace thelayers of the aperture nonwoven. This Phase Change paper or like wet-layproduct may be used in the layers of foam and nonwovens an is optionallymoldable. In fact, this paper product may be used with or without thePhase change Technology to enhance the moisture transfer in this linersystem. The natural and synthetic paper fibers may be included with foamwith or without Phase Change materials for disposable composite productsfor medical and industrial use. The moisture transfer breathable linercan be developed with or without the Phase Change Technology. The PhaseChange Technology can be applied to any layer in this moisture transfersystem. An option to Phase Change Technology is the microencapsulatedthermal glass or polymer spheres applied to a foam layer, a nonwoven orfabric layer. The air sphere may add insulation to the open cell foamsand the nonwovens in this invention. Suggested nonwovens and foams byDicon Technologies, Foamex, Freudenberg, Dupont, DTI, Gore or 3MNonwovens or the like are recommended. These glass or polymer spherescan be applied any fabric, insulated nonwoven, foam or the elastomericcomposite layer. The Dicon foam may include FOSSHIELD or antimicrobialfibers. Fossheild may be included in Freudenberg, Dupont, and DTInonwovens or the like. The preferred thermal embodiment in thisapplication is the selected THERMALFOSS composite manufactured by FossManufacturing which transfers moisture.

If encapsulation technologies fabric by Nextec, Toray, ASF or the likeis used in outer layer 80 as discussed herein, then it preferable to usea thermal composite, Thermolite, Foss nonwoven thermal composite(Thermalfoss) with or without foam or Thermolite or Thinsulate abuttingthe spacer fabric in layer 50.

In of a number of performance category the inner lining fabric materialabuts a thermal composite and a spacer fabric and outer shell fabric.The thermal fibers and composites are eliminated in warmer linerapplications.

The moisture vapor continues from the second foam or foam or nonwovencomposite material 30 through the mesh, or spacer fabric or the thirdfoam layer. The third foam layer may optionally incorporated the meshand be moldable. Alternatively as discussed, layer 50 be a thermalcomposite or a nonwoven foam composite. The moisture transfers throughabsorption or wicking through layer 50 to the outer shell fabric orthrough layer 70, a breathable membrane. The products and performancecriteria determine the selection in layer 50. The moisture vapors arethen passed through waterproof/breathable membrane layer 70 if applied.The moisture vapors are absorbed into waterproof/breathable membranepassed through to an outer layer of fabric 80, as shown in FIG. 4. Thewaterproof/breathable membrane 70 can be selected from a varietypresently available on the market. 2000/PLUS/STANDARD/1300, SECO-TEC,THINTECH, LAY-TEK, SYMPATEX WINDLER, SYNTHETIC ELASTIC, ENDURANCE,TRIAD, STORM-TEX, ACCUVENT by Enterprise Coating, eVENT ACTIVE COMFORT,eVENT DRYCOMFORT, ENTRANT DERMIZAX, ECLIPSE, ENDURANCE, ENTRANT eVENTDRYTRAIL by BHA, WINDSTOPPER by Gore and WITCOFLEX SUPER DRY FILM byBaxanden Chemicals (a hydrophilic membrane) are currently beingconsidered as well as numerous additional membranes in the marketplace.However, the membranes currently considered to be the preferred ones arecalled TX-1540 (application by Shawmut Mills) or membranes distributedby Harrison Technologies or Brookwood companies. TX-1540 is intended tobe an ultra-thin, skin friendly, moisture barrier that allows moisturevapors to escape while preventing outside water from penetrating. ThePhase Change Technology inclusive in a membrane by Outlast is anoptional in this moisture transfer liner or the Frisby or SchoellerCOMFORTEMP foams or Freudenberg nonwovens in combination with othermembranes or with encapsulation, waterproof films or finishes fabrics orfibers. Of the various encapsulation techniques, the one practiced byNextec is particularly advantageous. This invention suggests the use ofthe Phase Change Technology to enhance the thermal abilities of theliner materials. However, natural and synthetic thermal fibers andcombined foam and moisture transfer nonwoven composites are thepreferable embodiment in this moisture transfer system. Variations ofthese systems can accommodate sports apparel and protective clothing.

Also shown in FIG. 4 is an optional protective rim or cuff 90, made of areticulated moldable foam (by Foamex, for example). A spacer fabric byMuller Textil covered by a nylon blend or neoprene covered by LYCRA. Thecuff is optional in the alpine boot and snowboard boot. A pull tab 100,preferably made of nylon, is connected to the protective rim 90. In theadventure sports applications such as climbing shoes, an abrasiveprotective material 110 is provided adjacent to a tongue 300. Anotherabrasive protective material 120 is provided around the heed portion ofthe shoe. Abrasive protective material 120 is supplied by Schoeller,DuPont, Nam Liong or the like. This protective material is optional inall alpine, snowboard, skate and soft-shell liners and boots as well asfor protective gear for hockey and the like. The outer layer of fabric80 of the lining system has 200 to 6000 denier strength and is madewaterproofed by a breathable membrane, a film, finish or coating, orencapsulation technology or by using structurally knitted, waterrepelling fabrics. Encapsulation technology is the preferable embodimentfor waterproofing in this invention and developed by a company calledNextec, Inc. or Toray, Inc. (a Japanese company, ASF or the like).Optionally, Nextec Encapsulated Technology can be combined in a layer offibers or fabric with the Outlast THERMOCULE fibers or nonwovens byFreudenberg or the like. A breathable membrane and encapsulated fibersor fabrics by Nextec, Toray or the like may be combined in someperformance categories with or without Themocule fibers.

Frisby/Schoeller COMFORTEMP foam two and three layer compositesinclusive of inner lining materials and foam with or without PhaseChange Technology or a inner lining material, foam, knits or nonwovensbacking maybe applied in this liner system. In one embodiment theSchoeller composite or the like abuts a waterproof breathable membraneswhen applied in layer 70 or a encapsulated, film or finished exteriorshell fabric in layer 80. The two and three layer Schoeller compositeliner is an option in this moisture transfer liner. If the outer shellfabric is encapsulated then the Phase Change Technology by OUTLASTTechnology, Frisby Technologies, Schoeller, Wisconsin Global orFreudenberg, Dicon may be incorporated to the fibers, foam, nonwovens,or fabric in layers 50, 60 or 70 prior to encapsulation. The PhaseChange Technology regulating molecules can be incorporated into thespaces between the encapsulated fibers and may be inserted at the timeof encapsulation. The breathable membranes, coating, finishes and filmsif applied preserves the outer layer of fabric 80 and perform as awaterproof barrier for the rider's liners. If the encapsulationtechnology is applied to the outer layer of fabric 80, then thebreathable laminate membranes need not be used. The Phase ChangeTechnology is an additive and is option in this liner system. Thermalfibers and air sphere may be added to the foam or fabrics or nonwovenslayers with or without the Phase Change Technology.

The outer layer 80 may be any of the following materials, eitherindividually or in combination. These materials include nonwovensynthetic blends, kevlar and nylon, polyester blends, syntheticbreathable waterproof leather and fabrics, encapsulated fabrics andnonwovens or the like. Suggested fabrics by Daewoo, Schoeller, NAMLIONG, Nextec, Brookwood, Freudenberg nonwovens, DuPont and Toray,Cordura and Supplex nylon treated by Encapsulation Technologies byNectex or Toray, or the like. The outer shell layer 80 made of nylon,Kevlar, polyester fabrics, polymer or spacer mesh or spacer fabric. Thematerial combinations in layer 80 may be waterproofed by encapsulation,a waterproof breathable membrane, structurally knitting the fabric torepel water or coating and or finishing the fabrics with a waterprooffilm or spay. Preferably, the outer layer 80 is encapsulated or treatedwith a waterproof breathable finish or film.

The outer shell may not be waterproof in some performance categories.The outer shell preferably is a combination of one of theabove-mentioned materials abutting an elastomeric composite, an opencell foam composite or thermal nonwoven or thermal nonwoven composite.This ultra thin moldable composites may be applied to running, golf andlite-hiking footwear or technical apparel or a number of performanceproducts.

A preferable selection of Schoeller Textil blends such as Cordura,DUNAFIL TS70 and KEVLAR creates a fabric with abrasive properties ofleather but breathable and flexible. Another excellent option fromSchoeller Textil is of DYNAMIC EXTREME Cordura nylon or Cordura areanother excellent selection in layer 80. Waterproof/breathable fabricssuch as ENTRANT Gil, DERMIZAX, TUFLEX, GYMSTAR, DYNAMIC, or the like maybe used in a number of performance categories. Technical products demandspecific performance criteria. Selected engineered fibers and foamcombinations and layered constructions determine the success of themoisture transfer system and are detailed for each product andperformance level. The foam, foam composite, moisture transfer nonwoven,nonwoven composite, elastomeric composites and fabrics may be treatedwith an ionized solution to increase the moisture transfer capabilities.A foam composite is defined in this invention is an open cell foamincluding a moisture transfer nonwoven layer or nonwoven fibers or anopen cell foam backed by a moisture transfer nonwoven or alternatinglayers of foam and moisture transfer nonwoven. A nonwoven thermalcomposite is a needle punch nonwoven such as Thermolite, Thinsulite or aSSOFTHERM or the like or a blend of synthetic or synthetic and naturalfibers mechanically bonded to a open cell foam.

A moisture transfer nonwoven composite is a spun bonded or wet-lay blendof natural, synthetic fibers or a blend of these nonwovens fibers withor without the open cell foam and silver fibers added. The nonwovensynthetic fibers are optionally lobed, shaped or hollow fibers. Themoisture transfer nonwoven composite may be substituted in any layer offoam, thermal needle punched nonwoven or thermal nonwoven composite inthis liner composite system. In one embodiment the moisture transfernonwoven or mechanical bonding to an open cell foam.

A foam composite is open cell foam including, a nonwoven layer, polymermesh or all three. The nonwoven fibers may be synthetic or natural fiberincluded in one process during the formation of the foam. The foamcomposites may be substituted for the elastomeric composite or any foamlayer or nonwoven layer. Alternatively, the foam composite may abut amoisture transfer thermal composite. The foam composite is not to beconfused with an cellular elastomeric composite. The elastomericcomposite fuses the fibers and liquid polymer foam together with intensewater pressure. The foam composite adds the fibers or nonwoven layer toa liquid reactive polymer foam or frothed foam. In some cases the foamcomposite is heat set.

The inner lining materials or fabrics are an important part of thismoisture transfer system. The following fabrics and nonwoven materialsare preferably selected for their moisture transfer abilities may beused for the lining of the inner liner insert or lining outer moldableshell composite, however any fabric or material listed may be applied inthis composite construction.

The polyester looped terry blend by Coville, Kronfli or the like is anexcellent wicking fabric and can remove moisture rapidly when treatedwith a wetting agent or combined with chemically or naturally ionizedfibers. Suggested for hiking applications.

The anti-fungal, anti-microbial, DRI-LEX nylon and nylon blendedfabrics, like the polypropylene, is sanded and soft. The material isextremely comfortable and cool to the tough. Suggested for hiking andclimbing applications.

The polyester FIELDSENSOR fabric works well with those individuals whoprefer maximum performance. The liner absorbs moisture immediately.DRILINE by Milliken offers a similar response and contains LYCRA forproducts requiring stretch.

A polyester microfiber fabric, COMFORTEL and FORTEL SPUNNAIRE by Wellmanor DYETECH by Dyerburg, CONCEPT III or the like, is smooth to touch andwickable. A wetting agent may be added to assist in moisture transfer.

Coville Fabrics a Fleeced or Terry Polyester. Freudenberg NonwovensMaterials.

Calamari cerami polyester fleece is an excellent option for winterproducts.

Conductrol acrylic based conductive fibers may be combined in an numberof performance categories with natural fibers.

A structural knitted or woven natural blend of wool, cotton, corn, hempor kapok may be used as an inner lining fabric option In someperformance categories these natural fibers may be in combination withsynthetic fibers and have LYCRA or elastic fibers combined for stretchor a felted wool and Ssoftherm blend with silver fibers may be utilizedas the inner lining material. Alternatively, any of these inner liningmaterials may be backed with a flocked fiber blend of synthetic fiberssuch as polyester, acrylic, acetate, tencel or natural fiber such ascotton, wood pulp, lyocell, rayon or the like or the inner liningmaterial may be double-sided with one fiber on the face and anotherfiber or fiber blend on the back. Chemical ionized solutions, wettingsolutions and surfactants may be added to the foams, nonwovens, thermalnonwovens, fabrics and spacer fabrics in this moisture transfer system.

Exterior shell boot composites for in-line, hockey skates, alpine,climbing and hike boots and shoes or the like are discussed in FIGS. 18,19, 20. These moldable, breathable, moisture transfer exterior shellcomposites may be to be combined with a polymer skeleton framework insome options. The recently developed soft-boot for by Rossignol skis,Tecnica, Salomon are examples of a polymer skeleton and a nonwoven orfabric composite construction. This inventions realizes the need foradded moisture transfer exterior shell boot composite for the snowboardboot, ice and hockey skate, soft alpine boot and the like. Presently,the soft-shell alpine boot for down hill skiing is composed of a polymerskeptical framework combined with a non-breathable a synthetic orleather composite. These existing products do not transfer moisture. Infact the boots are often hot and wet and eventual cold. The polymershell is adhered to the existing synthetic or leather composite byadhesive, welding, fused, molding or the like. The existing soft-shellliners and boot composites are not breathable and discourage themoisture from evaporating. The invention presents moisture transferliner insert that successfully moves the moisture vapor through thecomposite layers to the surface material of the insert liner.

The insert liner improves the dry climate of the boot substantially.However the existing soft shell encompassing the insert liner is notbreathable and does not transfer moisture. The soft-shell bootconstruction can be develop to transfer moisture and increase theperformance of the existing boots on the market with the followingconstructions.

These composites may be used for protective gear, skates and hiking andwork boot application.

The soft-shell exterior composite layers in FIGS. 18,19, and optionallyin 21 aids in the transfer of moisture off the surface of the insertliner. The moisture travels through the layers of the inner liner insertand successfully moves through the outer shell composite layers. Theengineered fibers and foam layers of the soft-shell boot compositeabsorb and continue the transfer of moisture out of the boot. Thesoft-shell boot composite constructions are combined with the polymerskeleton and material. The soft-shell boot constructed with thesemoisture transfer and optionally waterproof composites and including theinsert liner realizes a total moisture transfer and breathable productwith the added benefits of thermal regulation and anti-microbialproperties.

This invention develops the following moisture transfer soft-shellcomposite to combine with skeletal polymer inclusive in the RossignolSkis, Salomon, Tecnica etc. soft-shell boot or the like.

The first layer in FIG. 18, 19, or 21 is a blend of natural fibers suchas cotton, kapok, hemp, wool woodpulp, lyocell or the like or a blend ofsynthetic fibers or natural and synthetic fibers. The nonwoven fibersmaybe treated with a wicking solution or with Transfer Dry FiberTechnology or Wisconsin Technology and maybe aperture. Alternatively, aknitted or woven polyester blend may be substituted for the nonwoveninner facing material. This layer is 820 and 830 in FIGS. 18 and 19.

Layer 822 and 832 is a thin variation of the moisture transfer needlepunch nonwoven composite described in the previous embodiment orTHERMALFOSS with or without a polyurethane coating. The exterior shellfabric is waterproof as discussed above. In one embodiment theTHERMALFOSS is needled or laminated to a aperture nonwoven orelastomeric composite abutting a foam and the inner lining material onone side and the exterior shell fabric. The nonwoven may be optionallycoated with a polyurethane breathable polymer to increase stiffness andadhesively bond the exterior shell material. Layer 822 and 832 may bereplaced with or a elastomeric composite, thermal nonwoven or nonwovencomposite. A polymer mesh by Naltex, Conwad or the like may be attachedto layer 822 or 823 in some performance categories.

In another embodiment a structural polymer mesh is combined with theopen cell foam in one process and bonded to or placed between theexterior shell material. The foam may contain synthetic or naturalfibers or both. The embodiment may also combine the nonwoven in the foamas the inner lining face material of the exterior shell composite. Thefoam composite may be replaced by a spacer material in some performancecategories.

In another preferable embodiment the exterior shell waterproofedcomposite is developed with an inner lining fabric or nonwoven abuttinga moisture transfer nonwoven composite or moisture transfer thermalnonwoven composite attached to an frothed foam such as those developedat Textile Chemical and Rubber, Dicon or the like and the exteriorfabric.

The frothed open cell foam may alternative be supplied by Hydrophillixor the like and may be hydrophilic. The exterior shell fabric is treatedwith a coating, encapsulation or a film and is breathable. Optionally,the inner lining fabric can be laminated to the foam and a nonwoven tothe exterior waterproof shell fabric. This composite construction ispreferable in the thinner applications such as the bouldering shoes andhockey, ice skate and bloudering, climbing shoes.

A foam or elastomeric composite or nonwoven blend may be laminated orwelded to the inner lining material and outer shell fabric in oneprocess accommodates another optional. The ultra thin moisture transfercomposite may additionally included a structural mesh or spacer materialto increase the rigidity and performance. FIG. 18 displays the mesh aslayer 824. The polymer mesh if needed may be included or inserted in anylayer in the exterior shell composite or inner liner insert. In oneembodiment the elastomeric is the inner lining material creating a twolayer moisture transfer composite system.

The exterior shell fabric may be a waterproof breathable leather,nonwoven, knit or woven blend. The preferable construction is anantibacterial nonwoven synthetic or synthetic and natural fibers needledtogether with open cell foam and silvers fibers attached to the exteriorshell fabric by a frothed foam. The thermal fibers may be manufacturedby DuPont, Gore, 3M, Freudenberg or Foss Manufacturing or the like. TheFoss nonwoven blend may be SSOFTHERM, with or with out foam. A nonwovenand foam composite.

It is preferable when utilized a waterproof breathable coating to selecta permeable hydrophobic coating with tiny pores built for moisture vaportransfer performance. An open cell foam or frothed foam may replace theneedle punch thermal composite in layer 110 nonwoven composite orthermal nonwoven composite. The foam may have a structural meshincorporated during development or the structural mesh maybe laminatedor welded to the foam or to layer 120. A nonwoven may optionally beinserted or laminated to the foam inner lining surface. Layer 120 is theexterior shell material comprised of nylon, polyester or KEVLAR blend,synthetic leather, leather or nonwoven. A breathable synthetic materialor leather is suggested such as that manufactured by Schoeller's or NAMLIONG.

A optional composite construction would incorporate a elastomericcomposite by FoxRun in layer 110 welded or fused to a nonwoven abuttinga foam including a structural mesh or an elastomeric welded to a knittedfabric in layer 100 and the synthetic shell fabric of the soft bootLayer 120. A similar composite construction may be used in layers 820 to826. The elastomeric composite may include a structural polymer mesh toincrease the liner integrity.

The insert footbed layer 200 of the moisture transfer liner is removableand constructed to move moisture downward and out away from the rider'sfoot. The inner lining material abuts an open cell foam that is weldedor laminated to an top sheet abutting a breathable moldable spacerproduct preferably by Muller Textil, Foxrun or the like. The bottomportion of the foam is preferably provided with a moisture transfernonwoven top sheet as described earlier. The insert footbed can be usedfor all applications in this invention and may contain a structuralpolymer mesh or spacer material in some applications.

The moisture transfer nonwoven top sheet may be eliminated in someoptions and may be a knitted or woven construction. Alternatively, thefoam and nonwoven combination can be replaced by the elastomericcomposite, the Foss thermal composite (THERMALFOSS), a nonwoven blend byDuPont, Freudenberg, 3M or Foss Manufacturing or the moldable spacerfabric in the footbed. The hiking and climbing shoes or work boots mayrequire a thinner option similar to the hockey and ice skate, boulderingshoe and cross country boots comprised of a inner lining material or, anelastomeric composite and a moldable spacer fabric. The elastomericcomposite may be welded or mechanically bonded to the spacer fabric. Infact the elastomeric composite can be in any combination in this footbedor liner system. The spacer fabric composite adds support and transfersmoisture downward. In a foot wear product such as a lite hiking shoe thetop three layer of inner lining fabric, elastomeric and a nonwoven wouldabut a molded polymer, foam or cork insert base.

The foot bed for the alpine or skate may also be constructed with amoisture transfer inner lining fabric, a Foss nonwoven blend with orwithout foam attached to a molded base made of polymer, foam or a spacerfabric. Hydrophilic frothed foam by Hydrophillix, Inc. maybe be appliedbetween the footbed shell fabric, the Foss nonwoven or the hydrophilicfrothed foam by Hydrophillix may be applied to a nonwoven layer abuttingthe top sheet fabric and attack to the molded insert footbed polymercomposite. The heel pocked foam or the spacer material protects the backof the heel. The foam and polymer mesh composite may be used to protectthe heel, toe or side walls of the footwear protect. This cushionprotector allows circulation in the heel. Toray's polyester FIELDSENSORfabric, Deercreek and Coville polyester and polypropylene fibers andblends micro-fleeced or EVOLON by Freudenberg are some of the preferablelining material for the foot bed or selected disclosed fabricspreviously mentioned. A slow recover foam may be used in performancefootwear, alpine boot or skate categories.

The alpine tongue 300 is one of the inner liner materials mentionedabove, especially the FIELDSENSOR polyester, fleeced polypropylene,LYCRA blend with INNOVA fiber, the polyester microfiber, the polyesterlooped terry or the fabrics by Malden Mills, looped polyterry, polyesteror polypropylene fleeced blends. This inner liner fabric 310 ispreferably laminated to a structural support foam composite backed by amoisture transfer nonwoven 320. The moisture transfer nonwoven abuts aspacer fabric or moldable foam 330 with or with out a polymer mesh andfibers and the exterior shell selected fabric. Preferably, the open cellfoam is 1/32″ or ¼″. Alternatively, layer 320 may be an elastomericcomposite or Foss thermal nonwoven composite welded, fused or laminatedto the moldable spacer material layer 330 and exterior shell fabric inlayer 340. Layer 330 may be a polymer mesh inclusive in a moldable opencell foam. The spacer fabric and polymer mesh in the foam may be omittedin some products or performance categories. The exterior shell fabric isselected from one of the outer fabrics mentioned and is partiallycovered by a molded perforated polymer 350 for protection and support inthe alpine boot. The tongue construction of the hiking and climbingshoes preferably utilizes the Foss and/or DuPont fibers or thermalfibers composite blends, moldable foam composite or the elastomericcomposite with an inner lining material and exterior selected fabric andthe spacer products may be eliminated. The hydrophilic open cellperforated foam 330 can take the shape of the foot bones and protect theupper foot from damage. The foam composite 320 can also be shaped toaccommodate the foot and protect the ankle bones. Optionally, a moldablespacer fabric by Muller, or the like, may also be used as portion 330.Alternatively, an open cell foam, preferably reticulated open cell foam,may replace the spacer product and be treated with a hydrophilic foamcoating by Hydrophollix, Inc. and molded to accommodate the anklefootbed, toe box or tongue. The open cell foam may also be treated witha wicking solution to increase its hydrophilic performance nature. Theabutting nonwoven is applied may be treated with the hydrophilic coatingor a wicking solution in a numerous areas in this moisture transfersystem. The treatment by Hydrophollix can be applied to any later inthis embodiment.

A moisture transfer material 340 lies over the breathable, hydrophilicopen cell foam with or with out the hydrophilic treatment or perforatedfoam 330. This moisture transfer material 340 is preferably. In oneembodiment, a moisture transfer spacer mesh product is combined with theexterior shell fabric 340 and wraps around the outer edge of the tongueto allow moisture vapors traveling from the upper foot area to escapethrough moisture transfer material 340 to the outer surface of thetongue. Alternatively, the moisture transfer material may be a foamincluding an moisture transfer nonwoven covered by a exterior shellmoisture transfer fabric or an elastomeric composite welded to anexterior shell fabric. Material 340 also aids in providing a softeredged tongue and can be a nylon and polyester blend binding of meshmaterial treated with a generic TEFLON for waterproofing.

Finally, as shown in FIG. 6, outer layer 350, which can be a breathablesynthetic leather (by Daewoo Corp. Nam Liong or Nectex in NYC forexample) or a material manufactured by Schoeller identified as SchoellerDYNAMIC (66502) or the like.

NAM LIONG fabrics in the ARMORTEX series are recommended for allexterior shell fabric options.

The liners are preferably provided with a pull tab 100 as illustrated inFIGS. 4, 9, and 10 on the back of cuff 90 constructed of a slow recoveryfoam (by Rogers, or the like) moldable spacer fabric or neoprene coveredby LYCRA. Optionally, cuff 90 can be omitted altogether. FIG. 9 shows anopened up version of the liner looking from the back of the moisturetransfer alpine liner or hiking boot. Located just beneath the LYCRAcovered neoprene cuff or spacer fabric covered with a breathablenonwoven or synthetic leather 90 is an abrasive grip fabric material410, such as manufactured by Schoeller, Inc., NAM LIONG or the like andreferred to by the number 6500. Below material 410 is a reflective gripcomposite material an option in the hiking boot or climbing shoeapplication is a highly abrasive fabric 110 as shown in FIG. 4. Fabric110 is preferable a KEVLAR, nylon Cordura, or the like. Finally, outershell fabric 80 is the same as that shown in FIG. 4, and can be any ofthe fabrics listed previously in connection with outer shell fabric 80.The nylon pull tab 100 allows the rider easy entry.

FIG. 10 shows the other side of the liner of FIG. 9. In FIG. 10, 510 canbe a ¼ inch moldable foam which has been punctured or a breathablemoldable spacer fabric or the like. 520 represents the combination ofthe moldable polymer flexible mesh and foam or the moldable polymerstructural mesh included in the foam developed process (in case themoldable foam is not used as depicted), the outer shell fabric. As inall of the figures, the arrows depict the flow of moisture. FIG. 11illustrates the toe portion 400 of the liner. Preferably, the toeportion 400 is constructed with an inner liner fabric 10, followed by afoam composite or Foss thermal composite material 30, followed by abreathable membrane if used 60 and finally followed by the outer fabric70. The exterior shell fabric as mentioned may be waterproofed byencapsulated, a coating or a finish or film. The foam material 30 caneither be a single foam, two foams, a foam composite or a moisturetransfer nonwoven composite, a Thermolite, a Thinsulite or the like andfoam combination, Foss thermal composite with SSOFTHERM and foam or anyof these in combination. Abrasive grip fabric is also shown.

A breathable membrane, coated fabric or an encapsulated fabric is anoption in the liner, hiking boot or climbing shoe.

The 6500 high abrasive fabrics manufactured by Schoeller, Inc., NAMLIONG or the like are optionally located on the back of the cuff and thetop of the toe box and heel. The KEVLAR and Cordura, STARLITE, Cordurafabrics and selected high abrasion moisture transfer nonwoven providecomfort and durability to the liners and are extremely strong andresistant to abrasion and allow for breathability and performance.

FIG. 12 illustrates a snowboard or alpine insert boot linerincorporating the lining system discussed above. The snowboard boot mayhave a removable or non-removable liner as discussed above for thealpine boot. The following elements of the snowboard boot are shown:numeral 610 represents a waterproof breathable synthetic leather or aleather by OutDry (Nextec), a KEVLAR fabric (made by Schoeller, or asimilar material), Schoeller, DuPont & Toray or the like, Cordura,DYNAMIC EXTREME, KEPROTEC, or DERMIZAX by Toray; numeral 615 representsmaterials similar to that of numeral 610, but can have different colorsfor aesthetic purposes; numeral 630 represents a KEVLAR or a materialmade by Schoeller, NAM LIONG, a synthetic material, leather or the like,with the heel portion being synthetic rubber, EVA, or the like,manufactured by Daewoo; numeral 635 represents an inner moisturetransfer material covering a breathable molded breathable foam orbreathable a spacer product numeral 640 represents a KEVLAR or Corduramaterial; numeral 650 represents some decorative piping made ofsynthetic leather, stitching, polymer or the like; numeral 655represents a pull tab made of nylon or synthetic leather; numeral 660represents the base of the boot which can be made of a syntheticpolyurethane; numeral 670 represents a reflective KEVLAR back; andfinally, numeral 675 represents an optional sock that can be insertedinto the boot with the permanent liner or removable insert liner ifdesired.

The sock 675 is made up of three or four layers and similar to the thinrace boot option. The first layer can be any of the inner linermaterials discussed above. The second layer is a layer of elastomericcomposite, foam composite or nonwoven composite, thermal nonwovencomposite, Themolite, Thinsulite, Gore nonwoven with or without foam orsilver fibers. The third layer is a material that absorbs and transfersmoisture such as a ionized nonwoven blend, polyester blend manufacturedby Deercreek fabrics, Menra Mills, NAM LIONG fabric treated with awicking solution or the like. This layer is optional. The preferableouter shell insert sock construction may be a three layer compositeconstructed of an inner lining material, a nonwoven composite with foamor without foam and silver fibers and an outer shell polyester meshwaterproof with a encapsulated, film or a finish. The inner liningfabric and outer shell layer material may be a nonwoven, knitted mesh ora woven construction. Encapsulation technology can also be applied tothe third layer by Nectex. Sock 675 can be used for additional warmthand is removable, unlike the shoe liner and can be insert into thesnowboard, alpine liner or the like, for extra warmth. The insert sockliner is breathable and preferable used in a boot where the liner is notremovable or there is no liner available. The three layers can beattached to one another by lamination, although mechanical bonding, orstitching, or ultrasonically bonded, can also be used. This insert sockliner is recommended for the all-weather boot by L.L. Bean or the like.

The alpine and snowboard race boot requires a thin moldable lineroption. The insert liner for the alpine race boot preferably isconstructed in following three options; Inner lining material abuttingan open cell foam backed with a moisture transfer nonwoven top sheet.The three layer composite is laminated to the Foss thermal composite anda spacer fabric material The exterior shell fabric is laminated to the aspacer fabric material.

In the second option the inner lining material is laminated to the Fossthermal composite and abuts the breathable moldable spacer fabric andexterior shell material.

In the third option the inner lining material is welded to elastomericcomposite, the moldable breathable spacer fabric and exterior shellmaterial.

Optionally, the exterior shell fabric may be a three layer compositeconstructed of foam, moisture transfer nonwoven and the exterior shellfabric. The three layer exterior composite may be attached to thebreathable spacer fabric and molded. In fact, any of the combinationsmay be molded and welded in this inventions.

The microfiber and chemical ionized technology disclosed above israpidly developing and changing and has greatly increased the potentialfor improved performance of such products alpine boot, provided thatthey are properly utilized as in the present invention. These newtechnical fibers, materials, foams and moisture transfer compositecombinations are part of rapidly developing technical textilestechnology industry. The present invention employs a combination offabric, foam, moisture transfer nonwovens, moldable spacer materials,breathable membranes, coating, finishes, films, structurally woven orknitted waterproof fabrics, ionized fabrics, encapsulated outer fabricsin such combinations that increase the performance of the products inwhich they are used as well as increase breathability. The breathablemembranes, coating and finishes are optional in alpine, hiking andclimbing shoes. The removable sock liner may be insert into rubber bootsand all weather boots or alpine products. The discussion above hasfocused upon snowboard boots, alpine boots, hiking and climbing shoeliners similar applications can be made with running shoes, helmets,protective gear or cross country boots, or in-line skates, gloves,accessories, sleeping bags, back packs and apparel with slightmodifications.

The snowboard boot liner, the various layers can be combined bylamination, mechanical bonding, stitch bonding, ultrasonic bonding or acombination of these two. The second and third layers would include afoam that contacts the first layer and is a germicidal, reticulated foamor a hydrophilic, open-cell foam, such as DuPont and VPF manufactured byFoamex, DRI-Z manufactured by Dicon with or without glycerin, COMFORTEMPby Frisby and Schoeller or the like. Alternatively, these layers can bea Foss thermal composite. An elastomeric cellular composite inclusive ofmoisture transfer nonwoven fibers or a open cell foam backed by amoisture transfer nonwoven apertured top sheet composed of wood pulp,polyester, rayon, lyocel, cotton, or polypropylene, in a single process.A foam composite may be used in combination with a thermal nonwoven.

The fourth layer is a hydrophilic, open cell preferably, (DuPont orVPF), a slow recovery foam, or Dicon Technologies foam, or polymerflex-guard mesh or a polymer flex-guard mesh inclusive in a open cellfoam or a polyester breathable spacer material (by Muller) or the likefor support. In this case, the open cell foam, DuPont is laminated to amoisture transfer nonwoven top sheet composed of wood pulp, cotton,polyester, lyocel, blend which abuts a waterproof/breathable membrane(fifth layer) if used. If the flex-guard polymer mesh is used it isinclude in the foam in one process or the flex guard is followed byanother layer of open cell (DuPont) with a moisture transfer nonwoventop sheet inclusive in the foam or abutting the waterproof/breathablemembrane or an encapsulated or waterproof breathable coated or filmedexterior shell fabric. If the spacer material is used to may or may notbe molded to accommodate the foot. The moisture transfer nonwoven topsheet may be eliminated in selected performance categories. Thebreathable spacer material abuts either a waterproof breathablemembrane, an encapsulated or coated fabric. The breathable spacermaterial may combined with a THERMOLITE or the Foss thermal composite.

The Phase Change Technology by OUTLAST, Frisby may be added to any layerin the liner system and may be combined with encapsulated fibers andfabrics. Phase Change Technology can be used in conjunction withstructurally knitted waterproof fabrics or fibers, or with theencapsulation fabrics by Nextec, Toray or the like. Encapsulation byNextec combined with the OUTLAST Technologies is an enhance option inthis embodiment, but is not essential in the products. If encapsulationis employed, then the fourth layer preferably includes THERMOLITE or theFoss thermal composite. If a non-removable liner is employed instead ofa removable liner, a waterproof-breathable thin film, finishes orcoating can be used instead of encapsulation or a waterproof/breathablemembrane.

The sixth layer in this removable shell liner may be Cordura, STARLITE,KEVLAR fabrics or the like. The STARLITE by Faytex Corp or Faytexbreathable series, Kevlar and Cordura's by Schoeller 6500, 14705, 13207,13632, 65563 etc. and NAM LIONG's ARMORTEX Series, DERIZAX and ENTRANTGil by Toray.

The exterior shell fabric is and preferably encapsulated or waterproofedwith a breathable thin film or coating.

Alpine Cross Country Boots

A liner for the alpine cross country boots has a first layer selectedfrom a group including polypropylene, nylon blend, polyester orpolyester blends, LYCRA or wool backed by cotton, wool, rayon, lyocel,acetate, acrylic, polyester or a nonwoven blend. The inner ling fabricor material may be an anti-microbial, anti-fungal INNOVA or ALPHA;sueded polyesters; polyester field sensor; looped polyester terry;Dri-line by Milliken, DRI-LEX DOESKIN or BABY KID or the like by FaytexCorp.; polyester DRI-LEX terry by Faytex; polyester fleeced blends orspacer fabric by Malden; and polypropylene backed by cotton by Coville.

Alternatively the three layer composite by Faytex, Dicon or the like mayabut the second layer.

The second layer in this embodiment may be a open cell foam, or amoisture transfer nonwoven composite, or a breathable moldable spacerfabric or the outer shell material. These material may be individuallyselected or in combinations in certain performance categories.

The second layer is a germicidal, open cell hydrophilic foam. It may beCOMFORTEMP by Frisby or DuPont with Phase Change Technologies or a foamby Dicon Technologies with or without glycerin. This foam can beprovided with or without a moisture transfer nonwoven top sheet. Themoisture transfer nonwoven top sheet can be selected from any of thematerials previously specified. Alternatively, the second layer may bean elastomeric composite or the second layer can be a open cell foamsuch as DRI-Z or DuPont or the like with a fiber integrated into thefoam during it's construction. This composite of fiber and foam iscreated in one process and may in some performance categories contain apolymer mesh such as that developed by Naltex or a webbing. The opencell foam with or without the polymer mesh may alternatively, contain afibers nonwoven sheet constructed of the above suggested fiberscontained in the nonwoven backing. The assist in the absorption andtransfer of the moisture passing through the moisture transfer system.

The third layer is a structural support foam or a breathable moldablespacer material by Muller Textil. The heel and arch may also have a slowrecovery foam or spacer fabric added for comfort. The thickness of thelayer of foam or spacer fabric and THERMOLITE may vary for performance.

The fourth layer is a thin layer of THERMOLITE, a hollow core polyesterfibers, THERMOLITE combined with a with a open cell foam with or without nature fibers such as corn fibers added. Optionally, the third layercan be a blend of moisture transfer synthetic or nature fibers blend orthe THERMALFOSS nonwoven composite with or with out DuPont thermalfibers or an open cell foam such as DuPont or the like with a moisturetransfer nonwoven top sheet made of wood pulp, lyocel, rayon, cotton,polyester, acrylic, acetate, corn or polypropylene. These nonwovenfibers in combinations or independently absorb and move moisture. Thefourth layer may be optional in some performance categories.

The fifth layer is optionally, a breathable waterproof/breathablemembrane which may be any one of the following: SECO at Shawmut Mills,THINTECH, THERMOLITE 2000/1300 standard, laytex, breathable membranes byHarrison Technologies, Sympatex, or ENTRANT Gil by Toray The OUTLASTMembrane can be used by itself, with another membrane or withencapsulation technology on the outer shell fabric, such as Nextec,Toray or the like

Alternatively, instead of the membrane, encapsulation technology or awaterproof breathable finish or film may be applied to the exteriorshell materials of the sixth layer and can achieve similar results.Optionally, a combination of Phase Change Technology and encapsulationfibers or fabrics by Nextec or Toray. If encapsulation is employed, thenthe fourth layer preferably includes THERMOLITE, a moisture transfernonwoven blend or THERMALFOSS composite.

The sixth layer is one of the following fabrics. Note that if thesefabrics are encapsulated, the waterproof/breathable membrane in thefifth layer may not be needed in combination. These fabrics include thefollowing: Cordura; LYCRA blends; STARLITE by Faytex Corp.; KEVLARfabric by Schoeller (14705, 6500, 13207, 13632, 65563, etc.); NAM LIONG,AROMRTEX Series, DuPont and Toray or the like, Cordura 2000 by DuPont,Dermizax and ENTRANT Gil by Toray, 3 or 4 ply Supplex; Mojave and Tudornylon and polyester blends by Travis; 6 ply Maxus nylon blends or thelike; and synthetic leathers by Daewoo, Inc., Nextec or moisturetransfer nonwovens by Freudenberg, Sisa or the like. These fabrics maybe used individually or in combination.

The seventh layer is a LYCRA covered neoprene, moldable spacer fabric orslow recovery foam or reticulated open cell foam ankle cuff.

The tongue for the alpine boot is similar to the tongue of the in-lineskate. The tongue of the cross country boot is similar to the snowboardboot. They can be constructed of DuPont molded foams with a moisturetransfer nonwoven top sheet or moldable spacer fabrics. A slow recoveryfoam can also be used as specified with the snowboard boot. The innerfabric is one or more of DRI-LEX, DRI-LEX Aero-spacer, polyesterFIELDSENSOR polyester by Toray, Freudenberg nonwovens, DRILINE byMilliken, polyester spacer by Malden, polar fleece INNOVA or ALPHApolypropylene by Coville or Deercreek fabrics, or DRI-LEX DOESKIN nylon,polyester blends sueded or fleeced or the like. The outer tongue fabricsare high abrasive fabrics constructed of KEVLAR and Corduras bySchoellar's or NAM LIONG and DRI-LEX Aero-Spacer (or other Aero-spacermaterials by Faytex, or the like, and breathable synthetic and naturalleathers by Daewoo, Nextec, or the like.

All the leather in this embodiment can be treated with OutDry by Nextec.

Hiking Boots

A liner for the hiking boot would include the following. The first layeris selected from a group including: polyester field sensor; looped polyterry; DRI-LEX composites by Faytex; Doeskin, baby kid, Cambrelle byFaytex; anti-fungal, anti-microbial polypropylene fabrics; INNOVA orALPHA fleeced polyester and polypropylene blends, sueded polyesterblends, COOL MAX or nylon blends, or the like. Any combination of thesemoisture transfer fabrics can also be used.

The second layer is a cellular elastomeric composite or hydrophilic opencell foam preferably DuPont, COMFORTEMP by Frisby/Schoeller or DRI-Z byDicon. The OUTLAST membrane is an option in this layer. If a foam isused, a moisture transfer nonwoven top sheet selected from previouslymentioned materials can be attached as a backing.

The third layer is a molded hydrophilic open cell foam preferably DuPontbacked by an aperture top sheet composed of cotton, polyester,polypropylene, Lyocel, rayon, or wood pulp, cotton or the like. Amoldable heel and ankle spacer fabric by Muller or the like may also beused in place of the third layer of hydrophilic foam. A breathablemoldable spacer fabric or foam may be added around the toe box and backcuff. A molded heel/ankle insert by Muller Textil is preferably alsoused.

The fourth layer optionally is a waterproof/breathable membrane whichmay be any one of the following: OUTLAST membrane by GatewayTechnologies combined with Seco-Tex, TX1540 (distributed by ShawmutMills), THINTECH, THERMOLITE 2000/1300 standard, Laytex, WILCOFLEX DRYor the like. The OUTLAST Technology may also be used independently ofthe breathable membrane and may also be coated to the outer fabric orfibers. Also, this membrane layer may be eliminated in some modelsdepending upon the hiker's needs. Alternatively, instead of thebreathable membrane, encapsulation of the fifth layer can be performedto achieve similar results. If encapsulation is employed, then the thirdlayer may be an open cell foam or a moldable spacer fabric, aTHERMOLITE, a moisture transfer nonwoven composite or a THERMALFOSScomposite. The Phase Change Technology may be applied to the moisturetransfer nonwoven, foam or fabric in this moisture liner system and maybe combination with outer shell encapsulated fibers and fabric, such asby Nextec, or the like.

The fifth and last layer is a combination of one or more of thefollowing: Corduras, Supplex Nylon, STARLITE, Tudor, KEVLAR, nylonblends, polyester nylon blends, and waterproof breathable synthetic andnatural leathers. Preferably, this layer is waterproofed by usingencapsulation, waterproof finishes or films or coatings. Waterprooftreatment to the exterior shell leathers, synthetic leathers and/ormaterials can be applied by OUTDRY by Nextec, DURAPEL PLUS, HYPER D-WRor ENTRANT G2-XT.

Elastomeric composite technology may be insert between the exteriorshell fabric and the breathable membrane if applied or the elastomericcomposite may about a moisture transfer nonwoven thermal blend one sideand the exterior shell fabric on the other side. Optionally, the thermalnonwoven composite may be abutting the exterior shell material.Furthermore, the breathable liner according to the present inventioncould also be added to clothing such as shirts, pants, gloves, helmets,backpacks etc., by omitting elements such as the structural mesh and byadjusting the number of foam material layers and their thickness. Forexample, clothing preferably has a wickable inner liner, followed by anelastomeric or an open cell foam 1/16, ⅛ and the outer shell fabric. Amoisture transfer nonwoven may or may not be laminated to the foam.Optionally, a breathable membrane abuts the foam or moisture transfernonwoven and is laminated to the outer fabric. The outer fabric may bewaterproofed by encapsulated, laminated to a breathable waterproofmembrane, coated with a waterproof finish or film, or structurally wovenor knitted to repel water. If encapsulation technology or a waterproofbreathable film or finish is applied to the exterior shell fabric thanthe breathable membrane may not be applied. Indeed, the amount of foammay be replaced by a nonwoven composite blend. Presently, this linersystem is combining a open cell foam abutting a open cell foam andencapsulated outer shell fabric as one embodiment Optionally, theFossThermal, THE RMOLITE or a nonwoven thermal or nonwoven compositecombined with foam may be used abutting the inner ling fabric and theouter shell fabrics.

This invention can also be used for industrial and medical applicationsby using polyester spun bonded filter products by TangerdingVlitesstoffe, Vitafiber, or the like, combined with alternatinghydrophilic foam layers and nonwoven blends. The nonwoven composites areconstructed to filter, absorb and transfer moisture and microscopicparticles.

OTHER APPLICATIONS

FIGS. 13-22 disclose various other embodiments of the present inventionas follows. FIGS. 13-18 show a detachable, removable insert liner forsoft shell skates and other products. These liners are inserts and canbe used in hockey skates and other types of footwear. The sameconstruction can be applied to a complete boot rather than an insert.This is shown in FIG. 19. FIG. 19 is an example of a complete skatecontaining the same materials as the inserts in FIGS. 13-18, and builtin the same way as these inserts.

FIG. 13 illustrates an insert (700) for an in-line skate or hockey skatewith a first portion enlarged. In FIG. 13, numeral 710 represents acomposite of one layer, two layers, or three layers. 710 shows outershell fabric, foam, nonwoven, with no top sheet—the top sheet is theouter shell fabric in this case. 710 can be an exterior shell fabric ormaterial abutting a cellular elastomeric composite, or the fabric can bebacked by a flocked fiber combination abutting the foam and followed bya nonwoven or a knit. Alternatively, the same combination may be usedwithout flocking. Optionally, layer 710 can be a single layer of fabricor material, or a double layer, including fabric or material abutting anonwoven. Preferably, the composite layer is a 3 layer construction offabric, foam, and nonwoven. Layer 720 is a spacer fabric. Optionally,layer 720 is a combination which may include multiple layers of foam andnonwoven. In some performance categories, 720 can be simply a foam or anonwoven. Layer 730 is a nonwoven, or a cellular elastomeric compositeor an inner lining fabric or material such as a knit.

FIG. 14 illustrates another embodiment of an insert (700) for an in-lineskate or a hockey skate with a second portion enlarged. 740 illustratesa one, two, or three layer composite. The top sheet can be optionallycomposed of: 1) a nonwoven or a knitted layer; 2) a nonwoven or a knitand a foam; 3) a nonwoven or a knit with a cellular elastomericcomposite; 4) a nonwoven and a foam composite. Layer 750, 760 and 770together compose a spacer fabric or a moldable foam with a mesh.Optionally the spacer fabric or foam with a moldable mesh may include anonwoven thermal such as Thinsulite or Thermolite with or with outsilver fibers by Foss Manufacturing or the like or a thermal compositemade of nonwoven fiber blends and silver fibers. The preferableconstruction replaces the 3 layers (750, 760, and 770) with a singlelayered spacer fabric. In some multilayer constructions, the specificlayers could be broken down as follows: 1) layer 750 may be a knit,woven, nonwoven construction, or foam, or an elastomeric composite; 2)layer 760 may be a foam, nonwoven or a combination of foam and nonwoven;3) layer 770 may be a knit, woven, nonwoven, foam, or an elastomericcomposite.

FIG. 15 illustrates another embodiment of an insert (700) for an in-lineskate or hockey skate with a third portion enlarged. 780 could be acombination of an outer fabric and a foam or a combination of an outerfabric a foam and a non-woven. 782 has many options. One combination isa foam with a mesh, a non-woven, another foam, and another non-woven. Asecond combination has a foam, a mesh, a non-woven, a second foam, and asecond non-woven. A third combination is a non-woven, a foam, a secondnon-woven and a non-woven composite manufactured by Foss. Optionally,all nonwoven layers may be a cellular elastomeric composite, and mayinclude silver fibers by Foss Manufacturing.

784 has three options. One option is a spacer fabric. A second option isa moldable foam. The third option is a combination of a foam and apolymer mesh, manufactured by Naltex.

786 has the following options. It could be an outer fabric plus a foamor a foam and non-woven composite (Foss composite). Another option is anouter fabric and an elastomeric composite. Finally, 786 could be a Fosscomposite and an elastomeric composite together with an outer shellfabric. In some performance products the layers of 782 are omitted. Itshould be noted here that all composite materials can be backed by aflocked fiber blend which may contain silver fibers.

FIG. 16 illustrates an insert (800) for a soft-shell alpine boot withfirst and second portions enlarged. 802 illustrates a compositeincluding an inner moisture transfer material, a foam and a nonwoven.802 may also be an inner moisture transfer material, abutting a nonwovenand foam composite or a cellular elastomeric composite. 804 illustratesa composite of a nonwoven a foam, a second nonwoven and a second foam.Alternatively, 804 may be composed of a foam and a nonwoven with silverfibers (this combination is an example of a moisture transfer thermal),and in some performance categories a cellular elastomeric composite maybe combined with a moisture transfer thermal. This whole layer can beeliminated in some performance categories. Nonwovens in this compositemay be replaced by a knitted fabric. 806 illustrates a spacer fabric ora breathable moldable foam. The moldable foam may include a polymermesh, with or without silver fiber blends, or other fiber blendsincluding wool fibers. In one option the silvers and natural blends abutthe spacer fabrics and may be followed by a thermal nonwoven layer.Thermal nonwovens such as Thinsulite and Thermolite he like may includethe silver fibers by Foss manufacturing. Layer 806 is a moisturetransfer thermal composite composed of a nonwoven, and foam blend. Thefoam with mesh can be followed by a nonwoven or another foam. The foamnonwoven composite may be constructed in the following ways: 1)foam-nonwoven-foam; 2) nonwoven-foam-nonwoven; 3)nonwoven-foam-nonwoven-foam-spacer fabric; 4)nonwoven-foam-nonwoven-spacer fabric. All of these combinations mayinclude silver fibers or fiber blends and are considered moisturetransfer thermals. In some options, the nonwoven layer may be replacedwith a knitted layer, or a cellular elastomeric composite. 808illustrates a cellular elastomeric composite or a foam and nonwovenabutting an exterior shell fabric. The moisture transfer thermalcomposite may be combined with a polymer mesh and the exterior shellfabric in layer 808. Alternatively 808 can be the exterior shell fabricopen cell foam with or without silver fibers or fiber blends abutting anonwoven, a nonwoven thermal blend or a nonwoven and foam composite.This exterior shell composite is moldable, transfers moisture, andregulates temperature with fiber additions. The exterior shell fabricmay be waterproofed in the following ways: 1) with encapsulation; 2)with breathable membrane; 3) with waterproof breathable film or finish;4) with fibers treated or constructed to repel water. A preferablethree-layer construction for golf shoes, running shoes, cross-countryboots and apparel includes a waterproof exterior shell fabric, an opencell foam, or a cellular elastomeric composite abutting a knitted ornonwoven inner moisture transfer material. Optionally the foam, nonwovenor cellular elastomeric composite may include blends containing eithersilver or wool fibers, or both.

FIG. 16 also illustrates in layer 910 a spacer fabric abutting layer912. Optionally, 910 can be a foam with a fiber blend and polymer meshadded. 912 is preferably a moisture transfer thermal, composed of a foamnonwoven antimicrobial blend with silver fibers. Alternatively, 912 canbe a nonwoven thermal without foam or a thermal nonwoven with silverfibers. 914 is a one-, two-, or three-layer composite. It can be anouter shell fabric or material, abutting a breathable foam followed by anonwoven. Alternatively, the outer shell fabric may abut a cellularelastomeric composite or thermal nonwoven.

FIG. 17 illustrates an insert (800) for a soft shell alpine boot with asecond portion enlarged. 810 represents an outer shell fabric, a foamand a nonwoven composite. The 810 layer is preferably moldableantimicrobial thermal breathable, and transfers moisture. The 810 layercan be developed in a number of constructions. Layer 812 can be an outershell fabric and a breathable foam, an outer shell fabric a breathablefoam and a nonwoven, or an outer shell fabric and a cellular elastomericcomposite, or outer shell fabric and a moisture transfer thermal with orwithout foam. Layer 812 is a spacer fabric, which can optionally be abreathable foam with or without a polymer mesh and silver fibers orfiber blends. Layer 812 can be optionally be a moisture transfer thermalmoldable nonwoven composite, and in some performance categories the foamcan be replaced with a cellular elastomeric composite included in thenonwoven layer. Layer 810 and layer 814 are similar to each other inthis three-layer construction. Optionally, layer 814 can be a two-layerconstruction. Layer 814 illustrates a composite with an outer shellfabric and a foam, or an outer shell fabric and a nonwoven, or an outershell fabric and a foam, or an outer shell fabric and a cellularelastomeric composite. Preferably layer 814 is an outer shell fabric anda moisture transfer thermal composite including breathable foam andsilver fibers. Layer 816 is a moisture transfer thermal nonwoveninserted between the options in layer 814 and a spacer fabric in layer818, or a foam with or without a polymer mesh. Optionally, layer 816 canbe a foam nonwoven composite or a cellular elastomeric composite. Thismulti-layered composite abuts an inner lining material and forms themoldable liner insert or permanently attached liner. In some options,this liner may incorporate 3-15 layers. The spacer fabric in layer 818can optionally be a foam a nonwoven or a combination. Layer 18 may alsobe a foam with a moldable polymer mesh.

FIG. 18 illustrates a soft shell alpine boot (900) including insertssuch as that shown in FIGS. 16 and 17. In the enlarged portion of FIG.18, 820 illustrates an inner lining material. 822 illustrates a foamnonwoven composite and optionally 822 may be a cellular elastomericcomposite or a breathable foam. Layer 824 illustrates a polymer mesh.The polymer mesh in 824 can be included in a foam, or in a nonwoven, orin a foam and nonwoven composite, or alternatively it may abut layerswith any of these constructions. One option, layer 820 abuts a cellularelastomeric composite including a polymer mesh. Layer 826 illustratesanother inner lining material. 826 may alternatively be a nonwoven and acellular elastomeric composite or a knitted construction and abreathable foam or a three-layer composite composed of an inner liningmaterial, a foam and a nonwoven. Preferably, the pouter shell soft bootcomposite is composed of an outer shell fabric, a frothed open cellfoam, a moisture transfer nonwoven, or nonwoven composite and an innerlining material. This composite is moldable, transfers moisture, and isthermal and waterproof.

FIG. 19 illustrates a soft shell alpine boot (900) including insertssuch as that shown in FIGS. 16 and 17. In the enlarged portion of FIG.18, 830 illustrates an inner lining material. 832 illustrates a foamnonwoven composite and optionally 832 may be a cellular elastomericcomposite or a breathable foam. Layer 834 illustrates another innerlining material. 834 may alternatively be a nonwoven and a cellularelastomeric composite or a knitted construction and a breathable foam ora three-layer composite composed of an inner lining material, a foam anda nonwoven. Preferably, the pouter shell soft boot composite is composedof an outer shell fabric, a frothed open cell foam, a moisture transfernonwoven, or nonwoven composite and an inner lining material. Thiscomposite is moldable, transfers moisture, and is thermal andwaterproof.

FIG. 20 illustrates a polymer shell for a hockey skate 960 including amoisture transfer liner.

FIG. 21 illustrates a soft shell inline skate (950) incorporating any ofthe inserts of FIGS. 13-15. The soft shell inline skate does includesome polymer shell materials identified in 920. Similar material alsoforms a part of the soft shell alpine boot of FIG. 18 although notexplicitly identified. In some options, the polymer shell material in920 can be eliminated from the soft alpine or skate boot, and in otheroptions the shell material may be increased to provide more support.

All nonwovens, foams, fabrics, materials or composites can have fibersflocked to either one or both sides. The flocked fiber blend may includesilver fibers by Foss Manufacturing Co.

While the present invention has been described above in connection withthe preferred embodiments, one of ordinary skill in the art would beenabled by this disclosure to make various modifications to thedisclosed embodiments and still be within the scope and spirit of thepresent invention as recited in the appended claims.

Any composite constructions or combination of composites in thisapplication may be applied to technical apparel, casual sportswear,protective clothing, snowboard or biking helmets, accessories, in-lineskates, ice skates, hockey skates, medical and may have industrialapplications.

1. An indoor or outdoor performance action sports product having aseries of layers including a breathable, rapid dry, moisture transfer,thermal regulating performance comfort nonwoven insulation material,naturally adapting to temperature changes during active performancecombined with a water resistant or waterproof fabric or material or acombination thereof, comprising: a first layer compromised of abreathable, moisture transfer, knitted or woven fabric or nonwovenmaterial; a second layer comprised of a breathable, mechanically bonded,needlepunch nonwoven performance insulation material layer combiningdifferent, engineered, shaped polymer fibers, antimicrobial fibers andsynthetic and natural thermal and cooling fibers providing activemoisture transfer, rapid dry performance, and adjustable, thermal andcooling regulation during active performance comprising: shaped, lobedand grooved polymer fibers; and synthetic and natural thermal andcooling fibers naturally adjusting the product's thermal regulationduring active performance with the fiber combinations, engineered fibershapes and properties; and an exterior shell layer comprised of a wovenor knitted fabric, nonwoven material, leather material or a combinationthereof.